EB 8327 EN

Original instructions

SAMSON ROTACTOR® RP 3171
Rack&Pinion actuators
4th Generation Upgrade Series → AT1001U

Edition May 2022

Note on these mounting and operating instructions
These mounting and operating instructions assist you in
mounting and operating the device safely. The instructions arebinding for handling SAMSON devices. The images shown inthese instructions are for illustration purposes only. The actual
product may vary.
Î For the safe and proper use of these instructions, readthem carefully and keep them for later reference.
Î If you have any questions about these instructions,contact SAMSON‘s After-sales Service Department(samson@samsongroup.com).

The mounting and operating instructions for the devices are included in thescope of delivery. The latest documentation is available on our website atwww.samsongroup.com > Service & Support > Downloads > Documentation.

Definition of signal words! DANGER
Hazardous situations which, if not avoided, will result in deathor serious injury! WARNING
Hazardous situations which, if not avoided, could result indeath or serious injury! NOTICE
Property damage message or malfunction

Note
Additional information

Tip
Recommended action

EB 8327 EN

Contents

1
1.1
1.2
1.3

Safety instructions and measures. ................................................................................................................. 1-1
Notes on possible severe personal injury ....................................................................................................... 1-2
Notes on possible personal injury ................................................................................................................. 1-2
Notes on possible property damage ............................................................................................................. 1-2

2
2.1

Markings on the device. ............................................................................................................................... 2-1
Actuator nameplate sample .......................................................................................................................... 2-1

3
3.1
3.2
3.3

Design and principle of operation ................................................................................................................ 3-1
Direction of action and fail position .............................................................................................................. 3-1
Complementary/accessory parts .................................................................................................................. 3-2
Technical data ............................................................................................................................................. 3-2

4
4.1
4.2
4.3
4.3.1
4.3.2
4.4

Shipment and on-site tranport ..................................................................................................................... 4-1
Accepting the delivered goods ...................................................................................................................... 4-1
Removing the packaging from the actuator .................................................................................................... 4-1
Transporting and lifting the actuator .............................................................................................................. 4-1
Transporting the actuator .............................................................................................................................. 4-1
Lifting the actuator ....................................................................................................................................... 4-1
Storing the actuator ..................................................................................................................................... 4-2

5
5.1
5.2
5.3

Mounting and assembly .............................................................................................................................. 5-1
Preparation for installation ........................................................................................................................... 5-1
Control and signal devices assembly ............................................................................................................. 5-1
Mounting the actuator over the valve ............................................................................................................. 5-1

6Start-up ...................................................................................................................................................... 6-1

7

Operation ................................................................................................................................................... 7-1

8
8.1
8.2

Malfunctions ............................................................................................................................................... 8-1
Troubleshooting ........................................................................................................................................... 8-1
Emergency action ........................................................................................................................................ 8-1

9
9.1
9.2
9.3
9.4
9.5

Service ....................................................................................................................................................... 9-1
Preparation for servicing .............................................................................................................................. 9-1
Part list ....................................................................................................................................................... 9-2
Disassembly ................................................................................................................................................ 9-5
Service operations ....................................................................................................................................... 9-7
Reassembly ................................................................................................................................................. 9-7

10Decommissioning ........................................................................................................................................ 10-1

11

Removal ..................................................................................................................................................... 11-1

12

Repairs ....................................................................................................................................................... 12-1

13

Disposal ..................................................................................................................................................... 13-1

14

Certificates ................................................................................................................................................. 14-1

15
15.1
15.2
15.3

Annex ........................................................................................................................................................ 15-1
Tools ........................................................................................................................................................... 15-1
Tightening torque ......................................................................................................................................... 15-3
Lubricants ....................................................................................................................................................15-4

16
16.1
16.2
16.3

Rubber products storage instructions ............................................................................................................ 16-1
Overview .................................................................................................................................................... 16-1
Storage conditioms ...................................................................................................................................... 16-1
Storage life ................................................................................................................................................. 16-2

EB 8327 EN﻿

4

EB 8327 EN

Safety instructions and measures

1 Safety instructions and measures
Intended use
The SAMSON ROTACTOR RP 3171 actuators are designed
for the automation and operation of quarter-turn valves suchas butterfly valves, ball valves and plug valves in both indoor
and outdoor applications. Depending on the configuration,
the actuator is suitable for on/off or modulating duties. The
actuator can be used in process and industrial plants.
The actuator is designed to operate under exactly definedconditions (e.g. temperature, pressure, travel). Therefore, operators must ensure that the actuator is only used in operating
conditions that meet the specifications used for sizing the actuator at the ordering stage. In case operators intend to use theactuator in other applications or conditions than specified,contact SAMSON.
SAMSON does not assume any liability for damage resulting
from the failure to use the device for its intended purpose orfor damage caused by external forces or any other external
factors.
Î Refer to the technical data and nameplate for limits andfields of application as well as possible uses.
Reasonably foreseeable misuse
The actuator is not suitable for the following applications:− Use outside the limits defined during sizing and by thetechnical data.
− Use outside the limits defined by the accessories connectedto the actuator.
Furthermore, the following activities do not comply with theintended use:
− Use of non-original spare parts.
− Performing service and repair work not described in these
instructions.
Qualifications of operating personnel
The actuator must be mounted, started up, serviced and repaired by fully trained and qualified personnel only; the accepted industry codes and practices are to be observed. According to these mounting and operating instructions, trained
personnel refers to individuals who are able to judge the work
they are assigned to and recognize possible hazards due totheir specialized training, their knowledge and experience aswell as their knowledge of the applicable standards.
Personal protective equipment
We recommend wearing the following personal protective
equipment when handling the SAMSON actuators:− Protective gloves and safety footwear when mounting or
removing the actuator.
− Eye protection and hearing protection while the actuator isoperating.
Î Check with the plant operator for details on further protective equipment.

Revisions and other modifications
Revisions, conversions or other modifications of the productare not authorized by SAMSON. They are performed at theuser‘s own risk and may lead to safety hazards, for example.
Furthermore, the product may no longer meet the requirements for its intended use.
Safety devices
The SAMSON pneumatic actuators alone do not have any
special safety equipment.
Warning against residual hazards
To avoid personal injury or property damage, plant operatorsand operating personnel must prevent hazards that could becaused in the actuator by the signal pressure, stored springenergy or moving parts by taking appropriate precautions.
They must observe all hazard statements, warning and caution notes in these mounting and operating instructions.
Responsibilities of the operator
The operator is responsible for proper operation and compliance with the safety regulations. Operators are obliged toprovide these mounting and operating instructions as well as
the referenced documents to the operating personnel and to
instruct them in proper operation.
Furthermore, the operator must ensure that operating personnel or third persons are not exposed to any danger.
These instructions should not supersede or replace any customer’s plant safety or work procedures. If a conflict arises between these instructions and the customer’s procedures, the differences should be resolved in writing between an authorizedend user‘s representative and an authorized SAMSON representative.
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as well as the referenced documents and observe the specified hazard statements, warnings
and caution notes. Furthermore, the operating personnel mustbe familiar with the applicable health, safety and accident
prevention regulations and comply with them.
Referenced standards and regulations− SAMSON actuators are designed, produced and classified according to the European Atex directive 2014/34/
EU and U.K. Regulation S.I. 2016 No. 1107 (as amended). Before using the actuators in potentially explosive atmosphere areas, verify the actuator compliance with therequired ATEX and UKCA classification.
Î Refer to the nameplate and the ATEX / UKCA safety instructions.
− SAMSON ROTACTOR RP 3171 actuators are SIL certificated.
Î Refer to the SIL Certificate available from SAMSON for
the SAMSON ROTACTOR RP 3171 actuators SIL capability.
− Referring to Machine Directive 2006/42/EC and U.K. Regulation S.I. 2008 No. 1597 (as amended), actuators are

EB 8327 EN

1-1

Safety instructions and measuresclassified as “partly machinery” (see Declaration of incorporation).
Therefore, the actuator cannot to be put into service until
the machinery and/or the final system, where the actuatoris incorporated, will be declared in compliance with therequirements of the Directive.
− The SAMSON pneumatic actuators are designed according to the criteria of- Article 1, paragraph 2. j) ii) of the Pressure equipment
directive (PED) 2014/68/EU.
-Part 1, section 4, schedule 1, paragraph 1. j) ii) of U.K.
Regulation S.I. 2016 No. 1105 (as amended).
− Therefore, according to the directive 2014/68/EU and
U.K. Regulation S.I. 2016 No. 1105 (as amended) they
are not to be considered pressure equipments.
Î Refer to the EU Declaration of Conformity available fromSAMSON.
− The SAMSON actuators are in compliance with the TR CU
10/2011 and TR CU 12/2011.
Referenced documentation
The further documents apply in addition to these mounting
and operating instructions:− Mounting and operating instructions for the valve, available from the valve manufacturer,− Mounting and operating instructions for control and signal
devices (positioner, solenoid valve, etc.) available from devices manufacturer,− ATEX safety manual,− SIL safety manual for use in safety-instrumented systems.

1.1 Notes on possible severe personal injury! DANGER
Risk of bursting due to incorrect opening of pressurized
equipment or components.
Pneumatic actuators are pressure equipment that may burst
when handled incorrectly. Flying projectile fragments or components can cause serious injury or even death.
Î Before starting any work on the actuator disconnect all
pneumatic / hydraulic / electrical supplies and discharge
the pressure from the actuator.
Risk of severe personal injury due to suspended loads falling.
Î Stay far from suspended or moving loads.
Î Close off and secure the transport paths.

1.2 Notes on possible personal injury! WARNING
Crush hazard arising from moving parts.
The actuator and the valve assembly contains moving parts,
which can injure hands or fingers.
Î Do not touch or insert hands or finger into moving parts.
Î Before starting any work on the actuator disconnect all
pneumatic / hydraulic / electrical supplies and discharge
the pressure from the actuator.
Î Do not block the movement of the pinion and the pistonsby inserting objects into the actuator.
Risk of personal injury due to preloaded and compressed
springs.
End caps are under tension due to compressed springs.
Furthermore incorrect spring cartidges disassembly could result in serious injury.
Î Before starting any work on the actuator disconnect all
pneumatic / hydraulic / electrical supplies and discharge
the pressure from the actuator.
Î Make sure that the actuator is in the closed position (0°)
while disassembling the end caps and the stop screws have been correctly removed.
Î Do not disassemble individual spring cartridges.
Î For spring cartidges service contact SAMSON.
Risk of lifting equipment tipping over and risk of damage tolifting accessories due to exceeding the rated lifting capacity.
Î Use only approved lifting equipment and accessories whose maximum lifting capacity is higher than the actuatorweight (including the packaging, if applicable).
Risk of personal injury through incorrect operation, use or
installation as a result of information on the actuator being
illegible.
Over time, markings, labels and nameplates on the actuator
may become covered with dirt or become illegible in someother way. As a result, hazards may go unnoticed and thenecessary instructions not followed. There is a risk of personal
injury.
Î Keep all relevant markings and inscriptions on the device
in a constantly legible status.
Î Immediately renew damaged, missing or incorrect nameplates or labels.

1.3 Notes on possible property damage! NOTICE

Risk of actuator damage due to the use of inappropriate
tools.
Certain tools are required to work on the actuator.
Î Do not use damaged tools. Refer to section 15.1 ‘Tools‘.

1-2

EB 8327 EN

Safety instructions and measures

Risk of actuator damage due to excessively high or low tightening torques.
Observe the specified torques on tightening actuator components (bolts and nuts). Excessive tightening torques lead toparts wearing out quicker. Parts that are not tightened enoughmay loosen.
Î Refer to section 15.2 ‘Tightening torques‘.
Risk of actuator damage due to the use of unsuitable lubricants.
The lubricants to be used depend on the actuator material andoperating temperatures. Unsuitable lubricants may corrodeand damage the components.
Î Use only lubricants approved by SAMSON . Refer to section 15.3 ‘Lubricants‘.
Risk of actuator damage due to incorrectly attached slings.
Î Do not attach load-bearing slings to the travel stop.

EB 8327 EN

1-3

Safety instructions and measures

1-4

EB 8327 EN

Markings on the device

2 Markings on the device
2.1 Actuator nameplate sample
01

ATEX 2014/34/EU: n° INERIS-EQEN 034870/19
UKSI 2016:1107 : CML 21UKEXT1358

02
03
04
05
06
07
08

II 2 G Ex h IIC T6...T5 Gb X
II 2 D Ex h IIIC T85°C...T95°C Db X

Model / Type: AT1001U S12 B
EN ISO 5211: F16+F25+F30-N-75DS
Operating Press.: Maximum 8 bar
S.N. : 1
Max Nm Min. Nm Manufacture MM/YY: 6/2022
Torque at 6 bar 1803
1309
90° Rotation - ASST
Operating Temp.: -40°C to +80°C
Ancillary Attach.: AA4
Pressure Conn.: G 1/2"
Made in Italy by AIR TORQUE S.p.A.

Fig. 2-1

17

18

19

09
10
11
12
13
15

16

20 21

Table 2-1
Position

Description

01

Product series and company logo

02

Actuator model

03

Standard reference and actuator attachment designationl

04

Maximum operating pressure05

Maximum operating pressure06

Output torque at specified supply pressure in Nm− for Double acting: Max. output torque = Nominal torque at 5,5 bar (Nominal pressure)− for Single acting: Max. output torque = Air Start output torque at specified supply pressure
Min. output torque = Spring End output torque07

Ancillary attachment, interface according to actuator size

08

Pressure connections and interface

09

ATEX technical documentation references

10

UKSI technical documentation references

11

ATEX / UKCA marking

12

CE marking

13

UKCA marking - UKSI 2016:1107 regulation

14

ATEX marking - 2014/34/EU Directive

15

Actuator serial number

16

Data Matrix Code17

Actuotor Rotation and Assembly type18

Air connections (Port 2 and Port 4 identification)

19

Country of origin and manufacturer‘s name20

Action and Rotation− for Double acting: direction of rotation while the actuator is pressurized through Port 2 or Port 4− for Single acting: direction of rotation while the actuator is pressurized through Port 2 and indication of fail safe direction for
spring action

21

Month (MM) / Year (YY) of manufacture

EB 8327 EN

2-1

Markings on the device

Note
Refer to the Catalogue T 8327 for actuators available options
and ordering codes.

2-2

EB 8327 EN

Design and principle of operation

3 Design and principle of operation
The SAMSON ROTACTOR RP 3171 rack and pinion actuators are devices for remote operation (on/off or modulating
duties) of different industrial valves such as ball valves, butterfly valves and plug valves.
The actuators are available in two configurations: double acting and single acting.
1. DOUBLE ACTING
Refer to Fig. 3-2.
In case of the double acting configuration air pressure will benecessary for both strokes (A and B).

A

The actuators can be controlled by different options:− direct mounting of control devices (for example a solenoid
valve or a manifold) with NAMUR interface,− threaded connections (to pressurize port “2“ and “4“) with air lines from separate electro-pneumatic control system.

3.1 Direction of action and fail positions
The standard rotating direction for the
SAMSON ROTACTOR RP 3171 actuators is clockwise to
close.
Standard SAMSON ROTACTOR RP 3171 actuators aredesigned for 90° rotating angle, with travel stop allowing
adjustment (Fig. 3-3) for ±5° on both close and open
positions.
Available stroke
adjustment

90°
“2“

“4“

“2“

“4“

95°

85°

B

5°

Fig. 3-1

0°
2. SINGLE ACTING-5°

Refer to Fig. 3-1.

Fig. 3-3

When air pressure is supplied through port “2“ (A‘) into theactuator body, the linear force applied on the piston surface
generates the pinion rotation, driving the valve to a defined
position. At the same time the actuator springs are compressed.

For single acting actuator in case of pressure, power or signal
failure the springs drive the actuator in the fail position thatcan be FAIL OPEN or FAIL CLOSE.

When air pressure is discharged (B‘), the springs are automatically released, driving the rack and pistons back to theoriginal position and thus the valve to the fail-safe position.

Note
If the actuator is controlled by a control system the FAIL position may be different from FAIL OPEN or FAIL CLOSE.
Î Refer to the actuator model technical data for the FAIL position.

A‘Î Refer to section 2.1 ‘Actuator nameplate sample‘ (Table
2-1, position 11) for the fail action and direction of rotation available options.
“2“

“4“

“2“

“4“

B‘

Fig. 3-2

EB 8327 EN

3-1

Design and principle of operation

3.2 Complementary/accessory parts

3.3 Technical data

Gearbox

The nameplate provides information on the actuator configuration.

It is an emergency manual override system designed toprovide manual operation to drive the actuator and the valve
in the safe position when the supply pressure is not available
in case of any emergency situation. The actuator and thevalve are operated rotating a handwheel. (Fig. 3-4)
Î Refer to the gearbox instruction manual available fromSAMSON.
! NOTICE

Risk of actuator damage due to incorrect gearbox stroke
adjustment.
− Make sure that the actuator and the gearbox are correctly
oriented, with reference to the rotation direction required.
− Make sure that the stroke of the gearbox does not exceed
the stroke allowed by the actuator.

Î Refer to section 2.1 ‘Actuator nameplate sample‘.
Î More informations are available in the actuator modeltechnical data sheet available from SAMSON.
Power operating media− Use dry or lubricated air or inert gas.
− Make sure the operating media is compatible with the actuator internal parts and lubricant.
− In case of pressure medium different than Group 2 fluids
according to the PED 2014/68/EU, contact SAMSON.
− The operating media must have a dew point equal to–20°C (-4°F) or at least 10°C (18°F) below the ambient
temperature.
− The maximum particle size contained into the operating
media must not exceed 30 μm.
Supply pressure− The maximum operating pressure is:–

7 bar (101,5 Psi) for double acting actuators,–

8 bar (116 Psi) for single acting actuators.

Î Refer to section 2.1 ‘Actuator nameplate sample‘ (Table
2-1 and Table 2-2).
− For double acting and single acting actuators the working
pressure is from 2.5 bar (36 Psi) up to the maximum operating pressure.
GEARBOXÎ Refer to the actuator model technical data for output torque values related to the working pressure range.
Operating temperature
The nameplate provides indication on the operating temperatures.

Fig. 3-4
Block and safety lock-out system
The block and safety lock-out system permits to lock the actuator and the valve in specific cases, despite the fail action of
the actuator. (Fig. 3-5)
Î Refer to technical data T 8327–

“ST” actuators for standard temperatures from
-40°C (-40°F) to +80°C (+176°F).

–“HT” actuators for high temperatures from
-15°C (+5°F) to +150°C (+302°F).

–“LLT2” actuators for extremely low temperatures from
-60°C (-76°F) to +80°C (+176°F).

Î Refer to the data sheet T 8327 for the soft spare parts material and lubricant type in relation to the different working temperature ranges.
Stroking time

BLOCK AND SAFETY
LOCK-OUT SYSTEM

The stroking time depends on several factors such as supply
pressure, supply system capacity (tubing diameter, pneumaticaccessories flow capacity), valve type, valve torque, applied
safety factor, cycle frequency, temperatures, etc. Nevertheless,an indication of the stroking time in clearly defined conditions
is available in the actuator model technical data sheet.

Fig. 3-5

3-2

EB 8327 EN

Shipment and on-site transport

4 Shipment and on-site transport
The work described in this section is only to be performed byfully trained and qualified personnel.

4.1 Accepting the delivered goods
After receiving the shipment, proceed as follows:
1. Check the scope of delivery. Check that the specifications
on the actuator nameplate match the specifications in thedelivery note. See the ‘Markings on the device‘ section for
nameplate details.
2. Check the shipment for transportation damage. Reportany damage to SAMSON and the forwarding agent (refer to delivery note).
3. Determine the weight and dimensions of the units to be lifted and transported in order to select the appropriate lifting equipment and lifting accessories. Refer to the transport documents and to the actuator model Technical data
sheet.

Î Do not shorten the slings with knots or bolts or other makeshift devices.
Î Observe lifting instructions (see section 4.3.2).

Tip
Our after-sales service can provide more detailed transportand lifting instructions on request.

4.3.1

Transporting the actuator

The actuator can be transported using proper lifting equipment (e.g. crane or forklift).
Î Leave the actuator in its transport container or on the pallet to transport it.
Î Observe the transport instructions.
Transport instructions− Protect the actuator against external influences (e.g. impact).

4.2 Removing the packaging from the actuator− Do not damage the corrosion protection (paint, surface
coatings). Repair any damage immediately.

Do not open or remove the packaging until immediately before mounting the actuator.

− Observe permissible temperatures (refer to the section 3.3‘Technical data‘).

Leave the actuator in its transport container or on the pallet totransport it on site.

4.3.2

Dispose and recycle the packaging in accordance with thelocal regulations.

4.3 Transporting and lifting the actuator! DANGER
Risk of severe personal injury due to suspended loads falling.
Î Stay far from suspended or moving loads.
Î Close off and secure the transport paths.

− Protect the actuator against moisture and dirt.

Lifting the actuator

Observe the ruling regulations corcerning the lifting operations.
To mount large actuators onto the valve, use lifting equipment(e.g. crane or forklift) to lift it.
Do not drill extra holes into the actuator.
Do not use the actuator lifting points to lift the actuator andvalve assembly.

! WARNING
Risk of lifting equipment tipping over and risk of damage tolifting accessories due to exceeding the rated lifting capacity.
Î Use only approved lifting equipment and accessories whose maximum lifting capacity is higher than the actuatorweight (including the packaging, if applicable).

! NOTICE
Risk of actuator damage due to incorrectly attached slings.
Only attach load slings to vertically lift the actuator on its
own.The lifting points must not be used to lift the actuator andvalve assembly.
Î Do not attach load-bearing slings to the travel stop or toaccessories.
Î Do not use damaged or defective slings.

EB 8327 EN

Fig. 4-1
Use appropriate tackles and slings to lift the actuator.
Î Refer to technical data sheet for the actuator weight.

4-1

Shipment and on-site transport

Lifting instructions

Storage instructions− Secure slings on the object to be transported against slipping.

− Store the actuator in a clean and dry place.

− Make sure the slings can be removed from the actuator
once it has been mounted on the valve.
− Prevent the actuator from tilting or tipping.
− Do not leave loads suspended when interrupting work forlonger periods of time.
− Use a hook with safety latch to secure the slings from slipping during lifting and transporting.
− On request two threaded holes are available to lift the actuator by means of eyebolts or similar components asshown in Fig. 4-2. Do not lift the actuator and valve assembly from these lifting points.

− Temperature limits are defined by the rubber components
material.
Î Refer to the ‘Rubber components storage instruction‘ (T3.3.3.1 EN).
− When the valve and actuator are already assembled, also
observe the valve storage conditions. Refer to the valve
documentation.
− Protect the actuator against external influences (e.g. impact).
− Secure the actuator in the stored position against slippingor tipping over.
− Do not damage the corrosion protection (paint, surface
coatings). Repair any damage immediately.
− Protect the actuator against moisture and dirt.

aaLiftingpoint0°≤ a ≤ 45°
Liftingpoint− Make sure that the ambient air is free of acids or othercorrosive media.
− Do not place any objects on the actuator.
− Keep for future references the relevant technical documentation of the actuator.
− Do not remove the plastic plugs from the air connections.
Tip
Our after-sales service (samson@samsongroup.com) can provide more detailed storage instructions on request.

Fig. 4-2

4.4 Storing the actuator! NOTICE
Risk of actuator damage due to improper storage.
Î Observe the storage instructions.
Î Observe the rubber components storage instructions(T 3.3.3.1 EN).
Î Avoid long storage times. Contact SAMSON in case ofdifferent storage conditions or long storage periods.

Note
It is recommended to regularly check the actuator and the prevailing storage conditions during long storage times.

4-2

EB 8327 EN

Mounting and assembly

5 Mounting and assembly

5.3 Mounting the actuator over the valve

The work described in this section is only to be performed byfully trained and qualified personnel.

! DANGER

5.1 Preparation for installation
If the actuator was shipped already assembled over the valve,the setting of the actuator and control system (if any) shouldhave been already done by the valve manufacturer or automation center.
If the actuator was shipped separately from the valve, the setting of the actuator and control system must be done while assembling the actuator on top of the valve.
The actuator assembly on valve can be performed by:− Mounting directly the actuator over the valve interface− Assembling a bracket and a coupling between the actuator and the valve.

5.2 Control and signal devices assembly
The SAMSON ROTACTOR RP 3171 actuators can be controlled by directly mounted devices or remote control systems. Therefore SAMSON actuators have direct mounting interfaces(Fig. 5-1) in order to allow control and signal devices assembly (e.g. solenoid valve, positioner, switchbox, etc) and threaded connections for remote control systems.
Î Refer to the documentation available from control and signal devices manufacturers for mounting and operating instructions.

Top view
Switchbox
and bracket
Ancillaryattachments

Position
indicator

Risk of bursting in the actuator
Pneumatic actuators are pressure equipment that may burst
when handled incorrectly. Flying projectile fragments or components can cause serious injury or even death.
Î Before starting any work on the actuator disconnect all
pneumatic/hydraulic/electrical supplies and discharge thepressure from the actuator.

! WARNING
Crush hazard arising from moving parts.
The actuator and the valve assembly contains moving parts,
which can injure hands or fingers.
Î Do not touch or insert hands or finger into moving parts.
Î Before starting any work on the actuator disconnect all
pneumatic/hydraulic/electrical supplies and discharge thepressure from the actuator.
Î Do not impede the movement of the pinion and the pistonsby inserting objects into the actuator.
! WARNING
Risk of damage and malfunction due to torque limit violation.
Considering the maximum actuator output torque, the maximum air supply pressure and the maximum valve torque, according to ISO 5211, the actuator maximum transmissible
output torque must not exceed the torque limit in relation to
the available ISO flange and the drive shaft connection.
Î Refer to section 2 ‘Markings on the device‘ for nameplate
details.

! WARNING
Risk of personal injury due to preloaded and compressed
springs.
End caps are under tension due to compressed springs.
Furthermore incorrect spring cartidges disassembly could result in serious injury.
Î Before starting any work on the actuator disconnect all
pneumatic/hydraulic/electrical supplies and discharge thepressure from the actuator.
Î Make sure that the actuator is in the closed position (0°).
! NOTICE

Solenoid
valve
Fig. 5-1

EB 8327 EN

Risk of actuator damage due to excessively high or low tightening torques.
Observe the specified torques on tightening actuator components (bolts and nuts). Excessive tightening torques lead toparts wearing out quicker. Parts that are not tightened enoughmay loosen.
Î Refer to section 15.2 ‘Tightening torques‘.

5-1

Mounting and assembly

Before mounting the actuator over the valve, make sure thefollowing conditions are met:
− The actuator is not damaged.

− When fitting accessories over the actuators, assemble
them in such a way that the emergency controls are easily
accessible for emergency manual operation.

− The type designation, material and temperature range ofthe actuator match the ambient conditions (temperaturesetc.). Refer to ‘Markings on the device‘ in section 2 fornameplate details.

− Check that the exhaust ports are not obstructed.

− Check compatibility of the valve stem to the actuator bore.
The length, size and configurations must match.

− Make sure that the operating pressure media composition
used for the actuator operation meets the operating conditions given in this manual and corresponds to what the actuator was manufactured for. Refer to section 3 ‘Design
and principles‘.

− Check compatibility of actuator, valve and bracket bolting
pattern.
− Before fitting the actuator over the valve, make sure thatthe actuator and the valve are correctly oriented, with reference to the rotation direction and fail action required.
− Make sure that the tubing, fittings and seals connected tothe actuator are cleaned to prevent foreign matter/objects
entering into the actuator’s chambers.

− Remove the plugs from the actuator air connections during
installation and operation, protect and close the airconnections which may not being used immediately.

− It is the user responsibility to ensure that actuator and control components must be protected from electrical spikes,
surge and lightning strikes as well as all magnetic fields.
− Prevent any dangerous and/or corrosive substances in theworking environment enter into the internal chambers byusing adequate filters and/or solenoid valves and/or any
other appropriate system.

DIRECT MOUNTINGMOUNTING WITH BRACKET

Actuator

Actuator

Valveinterface

BracketValveinterface
Coupling

Fig. 5-2Refer to Fig. 5-2 and proceed as follows to mount the actuator over the valve:
1. Disconnect any electrical/pneumatic/hydraulic power
supply.
2. Lay out the necessary material and tools to have them ready during mounting.

5-2

3. The actuator is supplied in the fail position (for single-acting), so drive the valve in the right position as per the actuator fail position.
4. Clean the actuator‘s bore and the bottom flange.
5. Clean the valve and the actuator interface to remove completely any lubricant.

EB 8327 EN

Mounting and assembly

6. Place the bracket, if any, over the valve flange, tighten allbolts and nuts and apply the correct tightening torque.
7. Assemble the coupling at first into the valve stem before
the assembly of the actuator.
8. Lift the actuator.
! WARNING
Risk of damage due to incorrect alignment
Î Support the actuator with the lifting equipment until theconnection bolts are completely tightened.
Î Make sure to align correctly the dowel pins or the spigot,
if any.
9. Align the valve stem/coupling to the actuator’s bore.
10. Carefully lower the actuator and engage the valve stem/
coupling into the actuator’s bore without forcing and driving the actuator into the position only with the weight of
the actuator itself.
11. Fix the actuator over the valve flange/bracket with theconnection bolts.
12. Tighten the connection bolts at the correct tightening torque as per ISO 5211.

EB 8327 EN

5-3

Mounting and assembly

5-4

EB 8327 EN

Start-up

6 Start-up
The work described in this section is only to be performed byfully trained and qualified personnel.
! WARNING
Risk of personal injury during actuator air exhaust.
In case of pneumatic version the actuator is operated with air.
As a result, air is exhausted during operation.
Î Install the air exhaust components in such a way thatexhaust ports are not located at eye level and the actuator
does not discharge at eye level in the work position.
Î Use suitable silencers and vent plugs.
Î Wear eye and hearing protection when working near theactuator.

! WARNING
Risk of personal injury through incorrect operation, use or
installation as a result of information on the actuator being
illegible.
Over time, markings, labels and nameplates on the actuator
may become covered with dirt or become illegible in someother way. As a result, hazards may go unnoticed and thenecessary instructions not followed. There is a risk of personal
injury.
Î Keep all relevant markings and inscriptions on the device
in a constantly legible state.
Î Immediately renew damaged, missing or incorrect nameplates or labels.
Verify the compatibility and connect the actuator to the pressure supply line and/or to the control system, if any, with fittings and pipes as per actuator model and plant specifications.

EB 8327 EN

6-1

Start-up

6-2

EB 8327 EN

Operation

7 Operation
The work described in this section is only to be performed byfully trained and qualified personnel.
! WARNING
Risk of personal injury during actuator air exhaust.
In case of pneumatic version the actuator is operated with air.
As a result, air is exhausted during operation.
Î Install the air exhaust components in such a way thatexhaust ports are not located at eye level and the actuator
does not discharge at eye level in the work position.
Î Use suitable silencers and vent plugs.
Î Wear eye and hearing protection when working near theactuator.
! WARNING

The actuator can be operated after connecting it to the supply
line and adjusting the stroke.
Double acting actuators require alternate connection ports tobe pressurized and vented for stroking.
Single acting actuators work on air stroke or spring stroke bypressurizing or venting respectively the connection ports.
Î Refer to section 3 ‘Design and principle of operation‘.
Î Choose the accessories, control elements, tubing and fittings for adequate flow rates so as not to constrict flow orcause high pressure drop affecting the performance of theactuator.
Î In case the plant specifications require a supply pressure
for the actuator lower than the maximum supply pressure
marked in the actuator nameplate, label the actuator with
reduced supply pressure (e.g. “Max. supply pressure limited to ... bar“).

Crush hazard arising from moving parts.
The actuator and the valve assembly contains moving parts,
which can injure hands or fingers.
Î Do not touch or insert hands or finger into moving parts.
Î Before starting any work on the actuator disconnect all
pneumatic / hydraulic / electrical supplies and discharge
the pressure from the actuator.
Î Do not impede the movement of the pinion and the pistonsby inserting objects into the actuator.

! WARNING
Risk of personal injury through incorrect operation, use or
installation as a result of information on the actuator being
illegible.
Over time, markings, labels and nameplates on the actuator
may become covered with dirt or become illegible in someother way. As a result, hazards may go unnoticed and thenecessary instructions not followed. There is a risk of personal
injury.
Î Keep all relevant markings and inscriptions on the device
in a constantly legible state.
Î Immediately renew damaged, missing or incorrect nameplates or labels.

! WARNING
Risk of bursting due to pressurized external chambers ofspring return actuator, “Port 4” air connection.
Spring Return Pneumatic actuators are pressure equipmentthat may burst when pressurized incorrectly in the springchambers. Flying projectile fragments or components cancause serious injury or even death.
Î Only the internal chamber, “Port 2” air connection, of
spring return actuators must be pressurized.
Î Refer to section 3 “Design and principle of operation” forthe function details.
Î The use of close loop system is allowed.

EB 8327 EN

7-1

Operation

7-2

EB 8327 EN

Malfunctions

8 Malfunctions
The work described in this section is only to be performed by fully trained and qualified personnel.

8.1 Troubleshooting
Malfunction

Uneven rotation

Incomplete rotation

Loss of power

Possible reasons

Reccomended action

Inadeguate supply

Check the supply system and make sure that the supply pressure is correct.

Missing lubricant

Disassemble the actuator, lubricate all the sliding parts and reassemble theactuator.

Worn components

Disassemble the actuator, inspect and replace the worn/damaged components.

Control system

Make sure the control system components are correctly assembled. Checkthe control system documentation and contact the manufacturer.

Faulty valve

In case of actuator mounted over the valve, check the valve documentationand contact the manufacturer.

Incorrect stroke adjustment

Follow the indications in section 9.5.6 for correct stroke adjustment.

Foreign object left inside

Disassemble the actuator, inspect and remove any foreign object.

Incorrect assembly after maintenanceDisasseble and reassemble the actuator correctly.

Control system

Make sure the control system components are correctly assembled. Checkthe control system documentation and contact the manufacturer.

Faulty valve

In case of actuator mounted over the valve, check the valve documentationand contact the manufacturer.

Inadeguate supply pressure

Check the control system and make sure that the supply pressure is correct.

Supply pipe blocked, compressed or withsealing problems

Check all the tubing and fittings, remove any foreign object/damaged
component.

Actuator seals leakage

Disassemble the actuator, inspect and replace any damaged seals.

Blocked air exhaust hole

Remove plugs or foreign objects from the exhaust hole.

Faulty valve

In case of actuator mounted over the valve, check the valve documentationand contact the manufacturer.

NoteContact SAMSON after-sales service (samson@samsongroup.com) for malfunctions not listed in the table.

8.2 Emergency action
The plant operator is responsible for emergency action to be taken in the plant.

EB 8327 EN

8-1

Malfunctions

8-2

EB 8327 EN

Service

9 Service
The work described in this section is only to be performed byfully trained and qualified personnel.
! DANGER
Risk of bursting due to incorrect opening of pressurized
equipment or components.
Pneumatic actuators are pressure equipment that may burst
when handled incorrectly. Flying projectile fragments or components can cause serious injury or even death.
Î Before starting any work on the actuator disconnect all
pneumatic/hydraulic/electrical supplies and discharge thepressure from the actuator.

! WARNING
Risk of personal injury due to preloaded and compressed
springs.
End caps are under tension due to compressed springs.
Furthermore incorrect spring cartidges disassembly could result in serious injury.
Î Before starting any work on the actuator disconnect all
pneumatic/hydraulic/electrical supplies and discharge thepressure from the actuator.
Î Make sure that the actuator is in the closed position (0°)
while disassembling the end caps and the stop screws have been correctly removed.
Î Do not disassemble individual spring cartridges.
Î If spring cartidges service is necessary, contact SAMSON.

With the information given below, SAMSON provides the end
user with all the required information necessary for service.
Under normal conditions, the actuator requires only periodic
observation to ensure proper operation. However, due to critical working conditions and a natural components ageing effect even if properly stored, a preventive service program isessential to ensure good performance, safe operation and an
extended life of the actuator. SAMSON recommend to perform the service not later than reaching the first limit between
cycles number limit and time limit. One cycle consists of nominal 90° angular travel in both directions (i.e. 90° to open +90° to close).
Î Spare kits are available for seals and bearing replacement. (refer to the ‘Part list‘ in section 9.2)
Î Refer to the Rubber products storage instructions (T3.3.3.1
EN).
Table 9-1
ACTUATOR OUTPUTTORQUE RANGECYCLES NUMBER
LIMIT

3.000 Nm ÷ 8.000 Nm

50.0008.000 Nm ÷ 16.000 Nm

30.000TIME LIMIT
48 Months/4 years
from installation
or
60 Months/5 years
from production
date.

Cycles number limit and time limit have been defined for actuators with sizing safety factor at least 1.3 and operating at
specific conditions:− Supply pressure ≤ 5,5 bar.

! WARNING
Crush hazard arising from moving parts.
The actuator and the valve assembly contains moving parts,
which can injure hands or fingers.
Î Do not touch or insert hands or finger into moving parts.
Î Before starting any work on the actuator disconnect all
pneumatic/hydraulic/electrical supplies and discharge thepressure from the actuator.

! NOTICE
Risk of actuator damage due to excessively high or low tightening torques.
Observe the specified torques on tightening actuator components (bolts and nuts). Excessive tightening torques lead toparts wearing out quicker. Parts that are not tightened enoughmay loosen.
Î Observe the specified tightening torques in section 15.2.

Note− The product warranty becomes void if service or repair
work not described in these instructions is performed without
prior agreement by SAMSON‘s After-sales Service.
− Only use original spare parts by SAMSON, which comply
with the original specifications.

EB 8327 EN− Supply media: air or inert gas, not corrosive, dry or lightly lubrified, without impurity.
− Working temperature from 10°C up to 30°C.
Note
Any deviation from these operating conditions may affect therecommended cycles number limit and time limit.
Î For actuators with “HT“ or “LLT2“ operating temperatures(refer to section 3.3 ‘Technical data‘) the recommended
cycles number and time limit may be reduced by 50%.
Î For actuators operating in Safety instrumented systems
where a certain SIL level is required, cycles number limit
and time limit may be significantly reduced.

9.1 Preparation for servicing
1. Lay out the necessary material and tools to have them ready for the intended work.
2. Put the actuator out of operation referring to section 10‘Decommissioning‘.
3. Remove the actuator from the valve referring to section 11‘Removal‘.

9-1Service

9.2 Part list

19.2

60.1

39
19.1
19.0

02

18
08*

02.1

10

04
03
11*
08*
05*

04R

15*

03R

30
30R
41

221G
222G

09.1

11R

50*
21*
06*
01

19.6

12

19.5

40

17

16*
14*
42

13

60
60.1

13.1
07*
20*
02F
11*

04E

03E

11E

04F
24

32

03F

11F*

23

40F

Fig. 9-1

9-2

EB 8327 EN

Service

Table 9-2
PART N° 1)

UNIT Q.TY

01

1

OCTI-CAM (Stop arrangement)

02

2

ANTI BLOW-OUT STOP CAP SCREW

02.1 2)2

SPRING CLIP (Stop screws)

03

2

WASHER (Anti blow-out stop cap screw)

03E

2

03F
03R

2

04

2

04E

2

04F

2

04R

2

NOTE

for special “R“ construction models
for models with extra travel stop adjustment

DESCRIPTIONWASHER (External cap screw)
WASHER (Internal cap screw)
WASHER (Extra travel Stop adjustment screw)
NUT (Stop screw)

for special “R“ construction models
for models with extra travel stop adjustment

NUT (External cap screw)
NUT (Internal cap screw)
NUT (Extra travel Stop adjustment screw)

05*

◊

2

BEARING (Piston back)

06*

◊

1

BEARING (Pinion top)

07*

◊

1

BEARING (Pinion bottom)

08*

◊

2

THRUST BEARING (Pinion)

09.1*

◊•

2

O-RING (External chamber air connection)

1

THRUST WASHER (Pinion)
O-RING (Stop screw)

10
11*

◊•

2

11E*

◊•

2

11F*

◊•

2

11R*

◊•

2

for special “R“ construction models
for models with extra travel stop adjustment

O-RING (External cap screw)
O-RING (Internal cap screw)
O-RING (Extra travel stop adjustment screw)

12

2

PISTON GUIDE13

16

CAP SCREW (End cap)

13.1

16

WASHER (Cap screw)

14*

◊•

2

O-RING (End cap)

15*

◊

2

BEARING (Piston head)

16*

◊•

2

O-RING (Piston)17

max. 12SPRING (Cartridge)

18

1

SPRING CLIP (Pinion)

19.0

1

GRADUATED RING

1

POSITION INDICATOR

19.1
19.2

1

MULTIFUNCTION POSITION INDICATOR

19.5

1

TOP ADAPTOR

19.6

2

HEX SOCKET SCREW (Top adaptor)

2)

20*

◊•

1

O-RING (Pinion bottom)

21*

◊•

1

O-RING (Pinion top)

23

2

24

2

30

2

32

2

39

1

CAP SCREW (Indicator)

40

2

PISTON

40F

2

41

1

ACTUATOR INDENTIFICATION LABEL

421

END CAP LABELEB 8327 EN

for special “R“ construction models

INTERNAL CAP SCREW
EXTERNAL CAP SCREWEND CAPfor special “R“ construction models

for special “R“ construction models

THREADED END CAPTHREADED PISTON

9-3

Service

PART N° 1)

UNIT Q.TY

NOTE

DESCRIPTION

50

1

BODY

60

1

DRIVE SHAFT

60.1 2)

1

INTEGRAL DRIVE SHAFT

221G

2

for models with 50% extra travel stop adj.

STOP SCREW (extra travel Stop adjustment)

222G

2

for models with 100% extra travel stop adj.

STOP SCREW (extra travel Stop adjustment)

NOTES:
1) *Suggested spare parts.
		Components included in spare part kits are indicated as follows:		 ◊
included in complete spare parts kit
		•included in o-rings kit
2) Available on request

9-4

EB 8327 EN

Service

9.3 Disassembly! WARNING
Risk of personal injury due to unsuitable workbench and incorrect handling.
The total actuator approximate weight is from 250 kg up to
320 kg depending on the configuration. Heavy weight components can cause personal injuries and or get damaged if
not handled carefully.
Î Operate in a safe area on a workbench suitable for theactuator size and weight.
Î Make sure the equiptment and the tools (coupling, vice,...)
are suitable for the actuator size and weight.
Î Make sure the components are always correctly aligned
and in a stable position while servicing.

9.3.1− unscrew partially the stop screw (221G/222G/24) out
from the actuator, making sure that the stop screw(221G/222G/24) is not in contact anymore with the piston assembly.
Y > 80 mm

Y

02 03 02.1

1104

11 02F
04R
04E

03R
03E

30R/32

Position indicator and graduatedring removal

Refer to Fig. 9-1 and Fig 9-2.
− Remove cap screw (39), if any.
− Lift the position indicator (19/19.1) off the top drive shaft.
If necessary pry gently with a screwdriver.

221G
222G
24

− Lift the graduated ring (19.0) off the body, if any. If necessary pry gently with a screwdriver.

Fig. 9-3

39
19 / 19.1
19.0

Fig. 9-2

9.3.2

Stop cap screws removal

Refer to Fig. 9-1 and Fig 9-3.
− In case of special “R“ construction remove the cap screws(02F) along with the o-rings (11).
− Remove the spring clips (02.1), if any.
− Remove the nuts (04) and washers (03) (11) from the stop
screws (02) along with the o-rings (11).
− Unscrew the screws (02) at least 80 mm out from the body.

9.3.3

11R
11E

End caps disassembly

Refer to Fig. 9-1, Fig 9-4, Fig 9-5 and Fig. 9-6.
Disassemble one end cap at a time.
! WARNING
Risk of personal injury due to compressed springs.
End caps are under tension due to compressed springs.
Î Before starting any work on the actuator disconnect all
pneumatic / hydraulic / electrical supplies from the actuator and exhaust the pressure from the power module.
Î Make sure that the actuator is in the closed position (0°)
before disassembling.
Î Make sure that the stop cap screw nuts (04/04E/04F) have been correctly removed or loosen as per section 9.3.2.

! NOTICE
Risk of components damage due to incorrect disassembly.
During disassembly the end caps can be damaged due to uneven force generated by compressed springs.
Î Remove the end caps as shown in Fig. 9-4 keeping a
constant distance (A = B) between the actuator body andthe end cap interface.
Î Observe the specified sequence shown in Fig. 9-5.

In case of actuator with extra travel stop adjustment or special“R“ construction (Fig. 9-3):− loosen the nut (04R/04E),

EB 8327 EN

9-5

Service− Completely unscrew and remove the end cap screws (13)and washers (13.1).

A=B
A− Remove the end caps (30/30R/32).
− Remove the spring cartridges (17).
− Remove the o-rings (14). (Fig. 9-6)
Double acting actuators− Unscrew completely the end cap screws (13) and washers(13.1) as per the sequence shown in the Fig. 9-5.
− Remove the end caps (30/30R/32).
− Remove the o-rings (14). (Fig. 9-6)

B
Fig. 9-4

9.3.4

Pistons disassembly

Refer to Fig. 9-1 and Fig. 9-7.

5

60
60.1

1

40

50

3
13.1

7

16

8
13

15

4
2

6

Fig. 9-5
40
40

14

05

Fig. 9-730
30R
32

Holding the body (50) with a bench vice or a similar device,rotate the drive shaft (60/60.1) until the pistons (40) are disengaged.
− Remove o-rings (16), the piston backs (05) and the pistonhead bearings (15).

Fig. 9-6

9.3.5
Spring return actuators− Release the springs compression by partially unscrewing
each end cap screw (13) 1 turn at a time as per the sequence shown in Fig. 9-5 for 4/5 turns.
! WARNING
Risk of personal injury due to compressed springs.
End caps are under tension when the springs are compressed.
Î If there is still force on the end cap (30/30R/32) after
uscrewing the end cap screws (13) for 4/5 turns the spring
cartridge may have been damaged or the pistons are notcompletely closed: stop the disassembly and contact
SAMSON.

9-6

Drive shaft disassembly

Refer to Fig. 9-1 and Fig 9-8.
! NOTICE
Risk of spring clip damage due to incorrect disassembly.
During disassembly the spring clip (18) can get overstressed if
not carefully handled.
Î Use proper tools to disassemble the spring clip.
Î In case of spiral spring clip (18) refer to the disassembly
and reassembly instructions available from SAMSON.

− Remove the spring clip (18) by means of snap-ring pliers
or a screwdriver for spiral rings.

EB 8327 EN

Service− Remove the thrust washer (10) and the external thrust bearing (08).

Î Make sure the components are always correctly aligned
and in a stable position while servicing.

− Apply downward force to the top of the drive shaft(60/60.1), until it is partially out of the bottom of the bodyand remove the internal thrust bearing (08) and the octi-cam (01) .

Proceed as follows for the standard assembly of
SAMSON ROTACTOR RP 3171 actuators (AS-ST code indicated in the nameplate).

− Push the drive shaft (60/60.1) completely out of the body.
If needed, gently tap the top of the drive shaft (60) with aplastic hammer.
− Remove the drive shaft top bearing (06) and bottom bearing (07).
− Remove the drive shaft top o-ring (21) and bottom o-ring
(20).
18
10
08

02

18

50

09.1
08

Î Refer to the catalogue T 8327 for actuators different assembly codes.
! NOTICE
Risk of actuator damage due to the use of unsuitable lubricants.
The lubricants to be used depend on the actuator material andoperating temperatures.
Î Only use lubricants approved by SAMSON. Refer to section 15.3 ‘Lubricants‘.

06

9.5.1

21

Refer to Fig. 9-1, Fig. 9-9, Fig. 9-10 and Fig. 9-11.

Drive shaft reassembly− Place the drive shaft top bearing (06) and bottom bearing
(07).

60
60.1
07
01

Î Refer to the technical data sheet T 8327 in case of actuators with different function/rotation.

20− Lubricate and place the drive shaft top o-ring (21) andbottom o-ring (20).
− Lubricate the external surface of the bearings and o-rings
placed onto the drive shaft (60/60.1) as per the Fig. 9-9.

Fig. 9-806

9.4 Service operations
Inspect and clean every single component.
Inspect, clean and replace bolts, screws and nuts, if needed.

LUBRICATE

07

LUBRICATE

60
60.1

Discard and replace the damaged soft components available
in the spare part kits.
Î Refer to the spare parts kit data sheet [RP10600E] and to
the Rubber products storage instructions [T 3.3.3.1 EN].

21

20

Fig. 9-9

Clean and lubricate every o-ring housing.
Î Refer to the section 15.3 ‘Lubricants‘.

− Fasten the screws (02) from inside the body (50) until they
are outside the body for at least 80 mm. (Fig. 9-10)

9.5 Reassembly− Insert partially the drive shaft (60/60.1) into the body(50). (Fig. 9-10)! WARNING
Risk of personal injury due to unsuitable workbench and incorrect handling.
The total actuator approximate weight is from 250 kg up to
320 kg depending on the configuration. Heavy weight components can cause personal injuries and or get damaged if
not handled carefully.
Î Operate in a safe area on a workbench suitable for theactuator size and weight.
Î Make sure the equiptment and the tools (coupling, vice,...)
are suitable for the actuator size and weight.

− Place the octi-cam (01) through the body (50) onto thedrive shaft (60/60.1). Refer to the Fig. 9-11 for the correct placement of the octi-cam (01).

EB 8327 EN− Place the internal thrust bearing (08).
− Insert completely the drive shaft (60/60.1) into the body(50).
− Place external thrust bearing (08) and thrust washer (10).

9-7Service! NOTICE
Risk of spring clip damage due to incorrect assembly.
During reassembly the spring clip (18) can get overstressed if
not carefully handled.
Î Use proper tools to reassemble the spring clip.
Î Replace the spring clip (18) if it has been overstressed andloosened.
Î In case of spiral spring clip (18) refer to the disassembly
and reassembly instructions available from SAMSON.

− Lubricate the internal surface of the body (50) and the piston (40) rack teeth and place the piston guides (12).
− For special “R“ construction fasten partially the cap screw(23) in the piston (40F).

− Place the spring clip (18) by means of by means of snapring pliers or a screwdriver for spiral rings.

15

18

16
02

10
08

40F

05

50

18

23
40

Fig. 9-12

08
Y > 80mm
Y
60
60.1

01

02

Fig. 9-10! NOTICE
Risk of damage due to unsuitable workbench.
Heavy components can cause personal injuries and or get damaged if not handled carefully.
Î Make sure the coupling is suitable for the actuator size
and weight.
Î The coupling must be properly fixed to the workbench.
Î Make sure the components are always correctly aligned
and in a stable position.

STANDARD AND LOCK-OUT CONFIGURATION OCTI-CAM ASSEMBLY− Insert the female connection of the drive shaft (60/60.1)
in a properly fixed coupling joint. (Fig. 9-13)

OCTI-CAM− Make sure that the octi-cam (01) is in the right position as
per the Fig. 9-11 referring to the stop screws (02).

STOP CAPSCREWS− Rotate the body (50) about 40°-45° clockwise from top
view, as shown in Fig. 9-13. Make sure the octi-cam (01)is correctly oriented as per Fig. 9-13.

DRIVE
SHAFT
(top view)

01

DRIVE
SHAFT
(bottom view)

40
diagonal

parallelFig. 9-11
40° - 45°

9.5.2

02

Pistons reassembly

Refer to Fig. 9-1 and from Fig. 9-12 to Fig. 9-15.
Proceed as follows to reassemble standard
SAMSON ROTACTOR RP 3171 actuator pistons with a 90°
angle of rotation and clockwise to close. Refer to the technicaldata sheet T 8327 in case of actuators with different function/
rotation.
− Lubricate and place onto the pistons (40) the o-rings (16),piston backs (05) and the head bearings (15).

9-8

02
50

Fig. 9-13

EB 8327 EN

Service

9.5.3

End caps reassembly! WARNING
Risk of personal injury due to unsuitable workbench and incorrect handling.
Heavy components can cause personal injuries and or get damaged if not handled carefully.
Î Operate in a safe area on a workbench suitable for theactuator size and weight.
Î Keep the actuator in a stable position my means of proper
supporting equipment.
Î Make sure the components are always correctly aligned
while reassembling the end caps.

Fig. 9-14− Insert and press the two pistons (40) simultaneously inside
the body (50) until the pistons are engaged.
− Then rotate the body (50) anticlockwise from top view until the stroke is completed.
− With pistons completely closed (0° position) as per Fig.
9-15, referring to the axis of the body, the rotation obtained must be about over 0° up to 5°.
− With pistons completely closed (0° position) as per Fig.
9-15 the dimension “A“ must be the same on both sides.
90° position
01

40

01

− In case of actuator with extra stop travel adjustment or
special “R“ construction:–

fasten the stop screws (221G/222G/24) into the end
caps (30R/30E) as shown in Fig. 9-16.

–

lubricate and place the o-rings (11R/11E),–

place the washer (03R/03E) and fasten partially thenuts (04R/04E).

Î Refer to the data sheet [T 8327] for extra travel stop adjustment.
04R
04E

40

11R
11E

A

A

40

0° position

Assemble one end cap (30/30R) at a time.

40

5°Fig. 9-15

221G
222G
24

03R
03E
30R/32For special “R“ construction:− Fasten or unscrew the screws (23) to push the pistons in
the 0° position (Fig. 9-15).

Fig. 9-17− Lubricate and place the o-rings (11F) over the screws (23).

14− Fix the screws (23) in position tightening the nuts (04F)
along with the washer (03F).
30
30R
30E
23
03F

Fig. 9-16

EB 8327 EN

04F

40F

Fig. 9-18

9-9

Service

17

50

09.1

Î Assemble the end caps as shown in Fig. 9-21 keeping a
constant distance (A = B) between the actuator body andthe end cap interface.
Î Observe the specified sequence shown in Fig. 9-22.
A=B

40

A

B

Fig. 9-19− Place the end caps o-ring (14) into the groove as shown in
Fig. 9-18 making sure that the o-ring is stable in its
housing.
− Place the actuator in vertical position. as per Fig. 9-19.
− In case of spring return actuator, place the correct quantityof spring cartridges (Fig. 9-19) in the correct position as
indicated in Fig. 9-20 depending on the actuator configuration.

Fig. 9-21− Complete the fastening of the end cap screws (13) tightening 1 turn at a time for each screw in th sequence
shown in Fig. 9-22.
Î Refer to the section 15.2 ‘Tightening torques‘. (Table 15.1)− Lubricate and place the o-ring (09.1) over the body (50).
(Fig. 9-19)

3

13.1

5

6
13

Side B

8

2

4

1
7

Side ASide A

Fig. 9-22

9.5.4

Position indicator reassembly

Refer to Fig. 9-1 and Fig. 9-23.
− Fix the graduated ring (19.0) into the body, if any.
Side B

Fig. 9-20− Place the indicator (19/19.1) referring to the correct actuator position.
− Fasten the indicator screw (39), if any. (Fig. 9-23)
39− Place the end cap (30/30R/03E).

19 / 19.1− Fix the end cap (30) fastening partially the cap screws(13) 1 turn at a time following the sequence indicated in
Fig 9-22.
! NOTICE
Risk of components damage due to incorrect assembly.
During reassembling the end caps can be damaged due touneven force generated by compressed springs.

9-10

19.0

Fig. 9-23

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Service

9.5.5

Stop cap screws reassembly

Open position

Refer to Fig. 9-1, Fig. 9-24 and Fig. 9-25.
− Lubricate and place the o-rings (11) over the body (50).
− Fasten the cap screws (02F), if any, making sure theo-rings (11) are correctly in position.
− Fasten the nut (04) along with the washer (03) onto bothstop screws (02).
− Assemble the spring clips (02.1), if any, after the stroke
adjustment (section 9.5.6).

− With the actuator in open position (90° position), screw or
unscrew the left stop screw (02) 1 turn at a time until thedesired stop position is achieved.
− Holding the stop screw (02) in position, tighten the stop
adjustment nut (04) to lock the stop screw (02) and assemble the spring clip (02.1).
Î Refer to the section 15.2 ‘Tightening torques‘. (Table 15.3)− Regulate the extra travel stop adjustment, if any.
Î Refer to the data sheet [T 8327] for extra stop travel adjustment.

9.5.7

11
02F

Mounting the actuator over the valve

Refer to the section 5.3 ‘Mounting the actuator over the valve‘.

Fig. 9-24

11

50

03

02.1

04 02
LEFT

Fig. 9-25

9.5.6

RIGHT

Stroke adjustment

Refer to Fig. 9-1 and Fig. 9-25.
Close position− With the actuator in close position (0° position) referring
to Fig. 9-15 for pistons position, screw or unscrew theright stop screw (02) 1 turn at a time until the desired stop
position is achieved. In case of spring return actuator, apneumatic supply may be necessesary.
! WARNING
Risk of personal injury due to pneumatic supply.
Stop screws are not still properly tightened. Any pneumatic
supply can eject the stop screws out from the actuator body.
Î Before starting pressurizing the actuator, make sure thestop screws are screwed at least for a legth equal to thescrew diameter. Refer to the ‘Tightening torques‘ (Table
15.3) for the screw dimensions.
− Holding the stop screw (02) in position, tighten the stop
adjustment nut (04) to lock the stop screw (02) and assemble the spring clip (02.1).
Î Refer to the section 15.2 ‘Tightening torques‘. (Table 15.3)

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9-11

Service

9-12

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Decomissioning

10 Decomissioning
The work described in this section is only to be performed byfully trained and qualified personnel.
! DANGER
Risk of bursting due to incorrect opening of pressurized
equipment or components.
Pneumatic actuators are pressure equipment that may burst
when handled incorrectly. Flying projectile fragments or components can cause serious injury or even death.
Î Before starting any work on the actuator disconnect all
pneumatic/hydraulic/electrical supplies and discharge thepressure from the actuator.

To decommission the actuator for service work or before removing it from the valve, proceed as follows:
1. Put the valve and its accessories out of operation in a safe
position. Refer to the documentation available from thevalve manufacturer.
2. Disconnect the pneumatic/electrical supply to depressurize the actuator. In case of single acting actuator, make sure the actuator reaches the FAIL position once depressurized.

! WARNING
Risk of personal injury due to preloaded and compressed
springs.
End caps are under tension due to compressed springs.
Furthermore incorrect spring cartidges disassembly could result in serious injury.
Î Before starting any work on the actuator disconnect all
pneumatic/hydraulic/electrical supplies and discharge thepressure from the actuator.
Î Make sure that the actuator is in the closed position (0°).

! WARNING
Risk of personal injury during actuator air exhaust.
In case of pneumatic version the actuator is operated with air.
As a result, air is exhausted during operation.
Î Wear eye and hearing protection when working near theactuator.

! WARNING
Crush hazard arising from moving parts.
The actuator and the valve assembly contains moving parts,
which can injure hands or fingers.
Î Do not touch or insert hands or finger into moving parts.
Î Before starting any work on the actuator disconnect all
pneumatic/hydraulic/electrical supplies and discharge thepressure from the actuator.
Î Do not impede the movement of the pinion and the pistonsby inserting objects into the actuator.

! NOTICE
Risk of actuator damage due to excessively high or low tightening torques.
Follow the specified torques to tighten actuator components(bolts and nuts). Excessive tightening torques lead to parts wearing out quicker. Parts that are not tightened enough may
loosen.

Î Refer to section 15.2 ‘Tightening torques‘.

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10-1

Decomissioning

10-2

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Removal

11 Removal
The work described in this section is only to be performed byfully trained and qualified personnel only.
Before removing from the valve, make sure the actuator is put
out of operation. Refer to section 10 ‘Decomissioning‘.
! DANGER
Risk of bursting due to incorrect opening of pressurized
equipment or components.
Pneumatic actuators are pressure equipment that may burst
when handled incorrectly. Flying projectile fragments or components can cause serious injury or even death. Before working on the actuator:
Î Before starting any work on the actuator disconnect all
pneumatic/hydraulic/electrical supplies and discharge thepressure from the actuator.

! WARNING
Risk of personal injury during actuator air exhaust.
In case of pneumatic version the actuator is operated with air.
As a result, air is exhausted during operation.
Î Wear eye and hearing protection when working near theactuator.

! WARNING
Risk of personal injury due to preloaded and compressed
springs.
End caps are under tension due to compressed springs.
Furthermore incorrect spring cartidges disassembly could result in serious injury.
Î Before starting any work on the actuator disconnect all
pneumatic/hydraulic/electrical supplies and discharge thepressure from the actuator.
Î Make sure that the actuator is in the closed position (0°).

! WARNING
Crush hazard arising from moving parts.
The actuator and the valve assembly contains moving parts,
which can injure hands or fingers.
Î Do not touch or insert hands or finger into moving parts.
Î Before starting any work on the actuator disconnect all
pneumatic/hydraulic/electrical supplies and discharge thepressure from the actuator.
Î Do not impede the movement of the pinion and the pistonsby inserting objects into the actuator.

DIRECT MOUNTINGMOUNTING WITH BRACKET

Actuator

Actuator

Valveinterface

BracketValveinterface
Coupling

Fig. 11-1

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11-1

Removal

Proceed as follows to remove the actuator from the valve referring to Fig. 11-1, making sure to not expose the plant toany risk:
1. Disconnect any electrical/pneumatic/hydraulic power
supply from the actuators and make sure the actuator itself
is depressurized.
2. Disconnect all electrical wirings of the control or signal devices, if any.
Î Refer to the control or signal devices documentation forsafe disassembly.
3. Remove the bolts and nuts from the valve flange and remove the actuator from the valve. Refer to the ISO 5211
for correct tightening torques.
4. Remove the coupling.
5. Remove the bracket from the actuator, if any.
6. Remove the control or signal devices, if any.
Î Refer to the control or signal devices documentation forsafe disassembly.

11-2

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Repairs

12 Repairs
If the actuator does not function properly according to how it
was originally sized or does not function at all, it is defective
and must be repaired or replaced.
! NOTICE
Risk of actuator damage due to incorrect repair work.
Î Do not perform any repair work on your own.
Î Contact SAMSON after-sales service(samson@samsongroup.com) for repair work.

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12-1

Repairs

12-2

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Disposal

13 Disposal
At the end of their life cycle SAMSON actuators can be completely disassembled and disposed sorting the components by
the different materials.
Î Observe local, national and international refuse regulations.
All materials have been selected in order to ensure minimal
environmental impact, health and safety of personnel during
their installation and maintenance, provided that, during use,
they are not contaminated by hazardous substances.
Oil, grease and electric components may require special treatment before disposal.
Î Contact waste management companies and/or local authorities.
! WARNING
DANGER
Risk of personal injury due to preloaded and compressed
springs.
End caps are under tension due to compressed springs.
Furthermore incorrect spring cartidges disassembly could result in serious injury.
Î Before starting any work on the actuator disconnect all
pneumatic / hydraulic / electrical supplies and discharge
the pressure from the actuator.
Î Make sure that the actuator is in the closed position (0°).
Î Do not disassemble individual spring cartridges.
Î For spring cartidges service contact SAMSON.
The disposal is to be performed by fully trained and qualified
personnel only.
− Decomission and remove the actuator (refer to section 10‘Decomissioning‘ and section 11 ‘Removal‘).
− Create a large area around the actuator in order to workin safe conditions without obstacles that can interfere withthe disposal operation.
− Dismantle the actuator sorting the components by the different materials.

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13-1

Disposal

13-2

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Certificates

14 Certificates
The following certificates and documents are available from SAMSON:− EU Declaration of Conformity,− ATEX Directive 2014/34/EU,− SIL Certificate,− Machine Directive 2006/42/EC,− DNV Type Approval− IP67 and IP68 Degree of protection,− TR CU 010/2011,− UKCA certification.

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14-1

14-2

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Annex15 Annex
15.1 Tools
15.1.1 Tools list
− WRENCH− CIRCLIP PLIER− TORQUE WRENCH− ALLEN KEY− SCREWDRIVER

Fig. 15-1

15.1.2 Tools dimensions

Ch 1− Stop screws (02) and nuts (04); end cap screws (13).

Ch 2 (mm)

Ch 3 (mm)

60

24

14

Ch 3

Ch 2

Ch 1 (mm)Fig. 15-2

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15-1

Annex− Extra travel stop adjustment screws tools (50% and 100% adjustment).
Ch 5

04R
221G/222G

04R

Ch 4 (mm)

Ch 5 (mm)

30

60

221G
222G

Ch 4

Fig. 15-3− Special “R“ construction.
Ch 9

Ch 7

23
04E

24

04F

Ch 6

Ch 10

24

04E

04F

23

Ch 6 (mm)

Ch 7 (mm)

Ch 8 (mm)

Ch 9 (mm)

30

60

60

30

Fig. 15-4

15-2

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Annex15.2 Tightening torques− All the tightening torques are intended in Nm.
− Tightening torque tolerance: ±10%.
− The tightening torques are based on a friction coefficient of 0.12 with a lubricated fixing elements (bolts or nuts) threads.
− After long operating times or use at temperatures above 80°C, the breakaway torque may be significantly higher.
Table 15-1: End cap screws (13) or nuts (13.2)

Table 15-2: Extra travel stop adjustment nuts (04R)

THREAD

TIGHTENING TORQUE (Nm)

THREAD

TIGHTENING TORQUE (Nm)

M16

150 ÷ 160

M39

1000 ÷ 1050

Table 15-3: Stop screws nuts (04)

Table 15-4: Pressure connection (if any)

THREAD

TIGHTENING TORQUE (Nm)

THREAD

TIGHTENING TORQUE (Nm)M391000 ÷ 1050

M5

4÷5

M6

8÷9

Table 15-5: Ancillary attachments

Table 15-6: Special “R“ construction nut (04F)

SIZE 1THREAD

TIGHTENING TORQUE (Nm)

THREAD

TIGHTENING TORQUE (Nm)

AA 4

M5

4÷5

M39

1000 ÷ 1050

AA 5

M6

8÷9

NOTE:
1. Refer to section 2.1 ‘Actuator nameplate sample‘.

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15-3

Annex15.3 Lubricants
The SAMSON ROTACTOR RP 3171 actuators are factory
lubricated for the life of the actuator in normal working
conditions.
Î Refer to the data sheet [T 8327] for Lubricant type in relation to the different working temperature ranges.

15-4

EB 8327 EN

Rubber products storage instructions

16 Rubber products storage instructions

In order to avoid deterioration protect the rubber products
from all sources of ionizing radiation.

16.1 Overview

Ozone

The information in this document applies to all the products
and/or parts supplied by SAMSON which include rubbercomponents. Rubber products and components are affectedby irreversible changes of material properties due to a naturalageing effect even if properly stored. Therefore in case of long
period of storage before use, make sure to store properly therubber products to minimize ageing deleterious effects.

16.2 Storage conditions
In order to minimize unwanted degradation of rubber products/components, it is recommended to keep stored productsin their original packaging. Moreover according to ISO 2230
observe the following conditions that may influence the storage:
Temperature
The preferred storage temperature should be below 25°C
(77°F) and the parts/products should be stored far away fromdirect heat sources. The minimum storage temperature in relation to the components operating temperature range is indicated in Table 1.
Table 16-1:
Operating temperature range

Minimum storage temperature

ST-40°C (-40°F)

HT-15°C (+5°F)

LLT2-60°C (-76°F)

However if the storage temperature is equal or below 15°C(+59°F), the rubber will stiffen and become susceptible to distortion if not handled carefully. Before the product is put into
service the storage temperature should be raised to approximately 30°C (+86°F).
Note
Storage at a 10°C (18°F) higher temperature will reduce themaximum storage life by about 50% and storage at a 10°C
(18°F) lower temperature will increase the maximum storage
life by about 100%.
Humidity

Provided that ozone is deleterious to rubber products, storage
rooms should not contain any electrical devices that can generate ozone, such as mercury vapor lamps or high-voltage
electrical equipment giving rise to electric sparks or silent electrical discharges.
Deformation
Rubber seals should be stored free from superimposed tensions or compressive stresses or other causes of deformation.
Cracking or permanent deformation may occur. Products haveto be stored in their original SAMSON packaging.
Contact with liquid or semi-liquid materials
During the storage the rubber components shall not be allowed to come in contact with any liquid or semi-solid materials(for example, gasoline, greases, acids, disinfectants, andcleaning fluids) or their vapours, different from the SAMSON
suitable lubricants.
Contact with metals
Rubber seals shall not be stored in contact with certain metals
and their alloys (in particular, copper, manganese, and iron)that have deleterious effects on elastomers. Products have to
be stored in their original SAMSON packaging.
Rotation of stock
Products should be taken from the stores taking care to perform a strict rotation so that the remaining products in store
are those of most recent manufacture or delivery. Indeed
SAMSON storage management performs a complete rotationof stock within 12 months for rubber components.

16.3 Storage life
The storage life is the maximum period of time that a rubber
product, appropriately packeged, may be stored from the manufacturing date. After this time the product is to be considered as unserviceable for the purposes for which it was designed. An extension storage period is applicable only to spareparts (and any other kit with rubber products) properly stored
into the original SAMSON packaging. In this case the rubber
products should be inspected and tested before the storage
life expiry (refer to Table 2) as specified in the standard ISO
2230. For SAMSON products and spare parts, the manufacturing date can be identified:Make sure that the relative humidity of the atmosphere in thestorage area is under 70%, especially in case of rubber products not stored in moisture proof sealed bags. Avoid condensation in the storage rooms.

–

by the date printed on packaging label or on the actuator
nameplate (Fig. 02, Fig. 03 and Fig. 04),–by the Product Serial Number (only for complete actuators). (Fig. 03 and Fig. 04)

Light

Referring to what described above and considering the different rubber materials properties and according to ISO 2230,
the suggested maximum storage life of rubber products is indicated in Table 2.

The rubber products must be protected from light sources, especially from direct sunlight or intense artificial light having ahigh UV content that could damage the products. It is preferable to store in dark areas without any sunlight exposure.
Radiation

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Rubber products storage life is not an exact science since it issignificantly affected by storage and handling conditions.

16-1

Rubber products storage instructions

However they should preferably be used within a period notlonger than 24 months.

Table 16-2:

Classification of Group

Rubbers Chemical Name and Abbreviation

Maximum storage life

Extension storage periods

A

Butadiene rubber (BR)
Isoprene rubber, natural (NR)
Isoprene rubber, synthetic (IR)Styrene-butadiene rubber (SBR)
Polyester urethane rubber (AU/EU)

5 years

2 years

B

Acrylonitrile-butadiene rubber (NBR)
Carboxylic- acrylonitrile-butadiene rubber (XNBR)Hydrogenated NBR rubber (HNBR)
Copolymer of ethylacrylate (or other acrylates) (ACM)
Chloroprene rubber (CR)
Isobutene-isoprene-rubber (IIR)

7 years

3 yearsC

Ethylene-Propylene copolymer (EPM)
Ethylene-Propylene Diene Monomer (EPDM)
Perfluoroalkyl or Perfluoroalkoxy (FKM)
Silicone and Fluorosilicone rubbers (VMQ, FMQ, ecc.)

10 years

5 years1.

Repackaging

2.

If SAMSON products are removed from storage for inspection
or testing and re-stored for a further storage period, theyshould be repackaged according to this document or with thesame original packaging.

Standard SAMSON packaging

Spare parts and kits with rubber components
If not otherwise specified, the SAMSON spare parts and kitswith rubber components are packaged in polyethylene transparent bags material not UV resistant, packed in carton orwood boxes as shown in Fig. 01.

KIT PACKAGING SAMPLEPOLYETHYLENE TRANSAPARENT BAG

CARTON BOX

Fig. 01

16-2

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Rubber products storage instructions

Kit packages are identified with external box labels (Fig .02).

KIT LABEL MINIMUM INFORMATIONSKIT LABEL SAMPLE

Position

Description

01

Spare parts description and referring actuator model

02

Part number of the kit (SAMSON Part Number)

03

Quantity

04

QRcode05

Kit manufacturing date

STD COMPLETE SPAREPART KIT 1000

01

Part Number: CRK-11000#SPN..CC

02

Quantity: 21 pcs.

03
Mounting
andOperatingInstruction:

09/06/2022

04

05

Fig. 02

Actuators
The SAMSON Rack and pinion and actuators are packaged in carton boxes and carton or wooded cases.
Store all the SAMSON products according to the related IMAT maintenance instruction manuals in order to guarantee the correct
product functions and performance.
Each actuator is identified by an external box label (only for rack and pinion actuators) and a label/nameplate placed directly
over the actuator. (Fig. 03 and Fig. 04)

RACK AND PINION ACTUATORSLABELS MINIMUM INFORMATION
Position

Description

01

Part number

02

Barcode and QR code03

Manufacturing month and year04

Manufacturing Country

05

Serial number

PACKAGING LABEL SAMPLE01

ACTUATORS LABEL SAMPLE
ATEX 2014/34/EU: n° INERIS-EQEN 034870/19
UKSI 2016:1107 : CML 21UKEXT1358

AT1001U S12 B F16+F25+F30-N-75DS

II 2 G Ex h IIC T6...T5 Gb X
II 2 D Ex h IIIC T85°C...T95°C Db X

01
02

X19 - 06/2022 Made in Italy
Fig. 03

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03

04

Mounting
andOperatingInstruction:

02

Model / Type: AT1001U S12 B
EN ISO 5211: F16+F25+F30-N-75DS
Operating Press.: Maximum 8 bar
S.N. : 1
Max Nm Min. Nm Manufacture MM/YY: 6/2022
Torque at 6 bar 1803
1309
90° Rotation - ASST
Operating Temp.: -40°C to +80°C
Ancillary Attach.: AA4
Pressure Conn.: G 1/2"
Made in Italy by AIR TORQUE S.p.A.

04

05
02

03

16-3

16-4

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EB 8327 EN

16-5

SAMSON AKTIENGESELLSCHAFT
Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany
Phone: +49 69 4009-0 · Fax: +49 69 4009-1507
samson@samsongroup.com · www.samsongroup.com

2022-06-17 · English

EB 8327 EN