GE AKD-8 User manual

DEH-41482
GE Energy
Industrial Solutions
Low Voltage Switchgear
Remote Racking Operator
For AKR Circuit Breakers
Cat. # AKREGRR
115 VAC, 60/50 Hertz
Operation and Maintenance Manual
BCS Switchgear Inc.
Switchgear | Circuit Breakers | Parts | Tech Support
bcsswitchgear.com | 888.599.0486
Need Help? 888.599.0486

Remote Racking Operator for AKR Breakers
2
TABLE OF CONTENTS
Section 1. Introduction.....................................................................................................................................3
Section 2. Receiving, Handling and Storage.......................................................................................3
Section 3. Description.......................................................................................................................................4
Section 4. Modification ................................................................................................................................10
BCS Switchgear Inc.
Switchgear | Circuit Breakers | Parts | Tech Support
bcsswitchgear.com | 888.599.0486
Need Help? 888.599.0486

Remote Racking Operator for AKR Breakers
3
Section 1. Introduction
The remote racking operator allows the user to
move a drawout circuit breaker between the
CONNECT, TEST, and DISCONNECT positions via
an electric racking motor and gearbox attached
to the front of the breaker. The remote racking
operator requires 115Vac, 50/60Hz control
power. A control box connected to the operator
with a thirty-foot cable permits control from a
remote location.
Prior to the initial use of the remote racking
operator, a one time modification must be
made to each breaker and breaker
compartment door.
The remote racking operator is portable and is
designed for attachment to the AKR Low
Voltage Circuit Breaker in AKD-8 Switchgear.
For all AKD-6 applications, contact a GE
Distributor.
Section 2. Receiving, Handling and Storage
2-1 Receiving and Handling
Each remote racking operator is carefully
inspected and packed for shipment. Immediately
upon receipt of the device, an examination
should be made for any damage sustained in
transit. If damage or rough handling is evident, a
damage claim should be filed immediately with
the transportation company, and the GE
Distributor should be notified.
The device should be removed from the shipping
box with sufficient care so that no damage will
result from rough handling. “Loose parts”
associated with the apparatus may be included in
the box. Care should be taken to make certain
that these parts are not overlooked. The shipping
box will include the remote racking device, two
couplers, two mounting brackets, and one
mounting plate to be used with AKR 30/50
breakers only.
The bracket for the AKR 30/50 breaker has a long
shaft that is welded to it while the bracket for the
AKR 30S, 75/100 and 125 breaker has a short
shaft welded to it as shown in Figure 1. Remove
the two wing nuts and washers that are attached
to the motor. Align the two holes in the bracket
with the studs on the racking motor. Reattach
and tighten the two washers and wing nuts to the
motor. Assemble the support plate to the AKR
30/50 bracket only by using the ¼-20 hardware
that was supplied and tighten.
2-2 Storage
The remote racking operator should be protected
against condensation, preferably by storing it in a
warm, dry environment at moderate
temperatures such as 40 degrees F to 100
degrees F. The storage area should be clean and
contain no corrosive gasses.
If the device is stored for any length of time, it
should be inspected prior to use to insure its
proper mechanical and electrical working
condition.
Su
pp
ort Plate
AKR 30/50
Bracket
AKR 30S, 75/100
and 125 Bracket
Remove
Wing
Nuts
Figure 1
AKR Racking Operator
BCS Switchgear Inc.
Switchgear | Circuit Breakers | Parts | Tech Support
bcsswitchgear.com | 888.599.0486
Need Help? 888.599.0486

Remote Racking Operator for AKR BREAKERS
4
Section 3. Description
3-1 Description of Small Frame Remote
Racking Operator – 800A-2000A AKR
Breakers
The remote racking operator consists of a drive
train, control switches, and attachment
brackets. The drive train is made of a gear
motor housing (1, Fig. 2), and a square drive
coupler (2, Fig. 2), which couples to the breaker
drawout mechanism.
Two control switches and a circuit breaker are
included with each remote racking operator.
The start switch (3, Fig. 2) housed in the hand-
held box (4, Fig. 2) controls the power to the
motor. Pushing the button closes the switch
and in turn supplies power to the motor. This
control switch is spring loaded; therefore,
continuous pressure on the button is required
to keep the motor running. The motor
directional toggle switch (5, Fig. 2) is mounted
on the motor housing. Two positions are
provided, “IN” and “OUT”. For racking toward
the CONNECT position, the switch should be set
to “IN”. For racking toward the DISCONNECT
position, the switch should be set to “OUT”. The
circuit breaker (6, Fig. 2) senses the motor stall
current when the breaker reaches the end of its
travel, which causes the motor to stall. The
higher motor stall current trips the circuit
breaker to the OFF position and in turn shuts off
the power to the motor. The latch rod (7, Fig. 2)
is designed to provide the means for attaching
the remote racking operator to the front of the
Small Frame Breaker. The latch rod (7, Fig. 2)
hooks into the breaker mounting clip (8, Fig. 2)
for mounting the remote racking operator to
the breaker.
Modification to Existing Small Frame Breakers
Before attaching the remote racking operator
to the existing AKR 30/50 and AKR 30s breakers,
mounting brackets must be added to the
breaker. On the AKR 30S breaker, a mounting
bracket must be mounted on the right side of
the breaker just above the existing racking
screw. Refer to page 6 for the installation
instructions and kit number.
On the AKR 30/50 breaker, a mounting bracket
must be added to the left side of the
escutcheon on the breaker frame. Refer to
page 7 for the installation instructions and kit
number.
Refer to pages 12 and 13 for field modification
to existing breaker doors.
ATTACHING / REMOVING DEVICE
Attaching the Remote Racking Operator to
the Small Frame AKR circuit breaker.
The circuit breaker must be in the OPEN position
before attempting to attach the remote racking
operator to the breaker. On the AKR 30/50
breaker, push the trip button and slide the
racking screw cover in the breaker escutcheon
to the right. Next, slide the remote racking
attachment cover on the cubicle door to the
left. This will expose an opening in the breaker
cubicle door. On the AKR 30S breaker cubicle
door, slide either the upper or lower racking
screw access cover (located on the upper right
corner of the breaker cubicle door) to the left.
This will expose two openings in the cubicle
door. Position the remote racking operator so
that the square drive coupling is aligned with
the square shaft of the drawout (racking)
mechanism and the ¼ -turn latch rod engages
the breaker frame. Push the remote racking
operator toward the breaker to engage the
square drive coupling with the shaft of the
racking mechanism. If the coupling and the
shaft are not in alignment, rotate the motor
shaft extension on the back of the motor
housing in either direction until the square drive
aligns with the square racking shaft. When they
are in alignment, the remote racking operator

Remote Racking Operator for AKR Breakers
5
will slide further through the breaker cubicle
door. Rotate the ¼ - turn latch rod counter
clockwise to lock the remote racking operator
to the breaker. Check the latch on the left side
of the remote racking operator to make sure it
is fully engaged into the breaker front cover
(indicated by the label on the latch).
Removing the Remote Racking Operator from
the Small Frame AKR Circuit Breaker.
Hold the remote racking operator securely and
rotate the latch release (located on the left side
of the remote racking operator) clockwise. This
should allow the remote racking operator to be
pulled from the breaker front cover. The
racking screw access covers will close
automatically.
Figure
2
AKR 30/50 Remote Racking Assembly
4 – Hand-Held
Control Box
3 – Start Switch
Push Button
30
-
foot cable
6- Circuit Breaker
Reset Toggle Switch
AC Plug
5 – IN/OUT
Directional
Toggle Switch
1 –Gear Motor
Housing
7 – ¼ turn latch/rod to
mount to breaker
2 – Square Drive
Coupling To Breaker
8 – Breaker Mounting Clip

Remote Racking Operator for AKR Breakers
6
Installation of the AKR 30S Remote Racker
Mounting Bracket Kit – AKR30SEGBRMOD
Locate the (2) 3/8 inch bolts on the right side of
the frame under the racking mechanism
assembly. Carefully loosen these two bolts in
order to slide the remote racking bracket
(supplied with kit) behind the lock washer that is
on the bolt. See below for location of the bolt
heads on the breaker frame. Be careful not to
remove these bolts.
Slide the bracket behind the lock washers on to
the bolts and then retorque the bolts to 25 – 35
ft.-lbs. Do not over torque. Check to see that
the bracket is completely vertical before
tightening. If not, this will cause improper
alignment of the remote racking shaft. The
breaker may now be reinstalled into the cubicle.
The existing racking screw mechanism needs to
be inspected for excessive wear and be
properly lubricated.
Loosen these (2) boltsMounting Bracket
Figure 3
AKR 30S Mounting Bracket Installation

Remote Racking Operator for AKR Breakers
7
Installation of the AKR 30/50 Remote Racker
Mounting Bracket Kit – AKR3050EGBRMOD
When looking at the front of the breaker, locate
the (2) mounting holes that are already
punched in the frame on the left side of the
escutcheon. They are located behind the
nameplate on the breaker.
Install the mounting bracket that came with
your kit. Align the (2) holes on top of the bracket
with the (2) holes on the frame. Install the (2) ¼-
20 flat washers, lock washers and bolts through
the frame and into the bracket. Torque the
bolts to 7 – 10 ft.-lbs. Do not over torque. Make
sure that the flat portion of the bracket with the
key way is facing outwards. See picture below.
After the bracket has been mounted, the
breaker is ready to be installed into the cubicle.
The existing racking screw mechanism needs to
be inspected for excessive wear and be
properly lubricated.
Nameplate
Mounting Bracket
Figure 4
AKR 30/50 Mounting Bracket Installation

Remote Racking Operator for AKR Breakers
8
3-2 Description of Large Frame Remote
Racking Operator – 3200A-5000A AKR
Breakers
The remote racking operator consists of a drive
train, control switches, and attachment
brackets. The drive train is made of a gear
motor (1, Fig 5) a square drive socket (2, Fig 5),
which couples the breaker.
Two toggle switches and a circuit breaker are
included with each remote racking operator.
The START switch (3, Fig 5) housed in the hand-
held box (4, Fig 5) controls the power to the
motor. Pushing the button closes the switch
and in turn supplies power to the motor. This
control switch is spring loaded; therefore,
continuous pressure on the button is required
to keep the motor running. The motor
directional toggle switch (5, Fig 5) is mounted on
the motor housing. Two positions are provided,
“IN” and “OUT”. For racking toward the
CONNECT position, the switch should be set to
“IN”. For racking toward the DISCONNECT
position, the switch should be set to “OUT”. The
circuit breaker (6, Fig 5) senses the motor stall
current when the breaker reaches the end of its
travel, which causes the motor to stall. The
higher motor stall current trips the circuit
breaker to the OFF position and in turn shuts off
the power to the motor.
The ¼ turn shaft (7, Fig. 5) is designed to provide
the means for attaching the remote racking
operator to the front of the Large Frame
Breaker. The latch rod (7, Fig. 5) hooks into the
breaker connecting bracket for mounting the
remote racking operator to the breaker.
ATTACHING / REMOVING DEVICE
Attaching the Remote Racking Operator to
the Large Frame AKR Circuit Breaker
The circuit breaker must be in the OPEN position
before attempting to attach the remote racking
operator to the breaker. Slide either the upper
or lower racking screw access cover (located on
the upper right corner of the breaker cubicle
door) to the left. This will expose two openings
in the breaker cubicle door. The upper opening
is for the ¼-turn latch rod and the lower
opening is for the square drive coupling.
Position the remote racking operator so that the
square drive coupling and ¼-turn latch rod are
aligned with the openings in the breaker cubicle
door. Push the remote racking operator toward
the breaker so that the square drive coupling
engages the square racking shaft and the ¼-
turn latch rod engages the breaker frame. If the
coupling and the shaft are not in alignment,
rotate the motor shaft extension on the back of
the motor housing in either direction until the
square drive aligns with the square racking
shaft. When they are in alignment, the remote
racking operator will slide further through the
breaker cubicle door. Rotate the ¼-turn latch
rod counter-clockwise to lock the remote
racking operator to the breaker.
Removing the Remote Racking Operator from
the Large Frame AKR circuit breaker
Hold the remote racking operator securely and
rotate the ¼-turn latch rod clockwise to release
the remote racking operator from the breaker.
Pull the remote racking operator away from the
breaker cubicle door. The racking screw access
covers will close automatically.

Remote Racking Operator for AKR Breakers
9
Racking Screw
Access Hole
7 - 1/4 turn latch/rod
to mount to breaker
1 - Motor and Gear
Housing
6 - Circuit Breaker Reset
Toggle Switch
5 - IN/OUT
Directional
Toggle Switch
4- Hand Held
Control Box
3 - Start Switch
Push Button
2- Square Drive
Coupling to Breaker
Figure 5
AKR 30S, 75/100 and 125 Remote Racking Assembly

Remote Racking Operator for AKR Breakers
10
Section 4. Modifications
4-1 Converting Large Frame Breaker to work with Remote Racking Operator
Figure 6
Connecting Bracket – Align 1st to
existing holes in breaker frame.
¼-20 Bolt, Nut, Lock Washer, Flat Washer – Add
¼ inch hardware to existing hole of bracket
and frame in upper position as shown.
3/8-16 Bolt, Nut, Lock Washer, Flat Washer –
Add 3/8 inch hardware to existing hole in
bracket and breaker frame in lower position
as shown.
Racking Stop – Align racking
stop with existing hole in
breaker frame as shown.
3/8-16 Bolt – Add 3/8 inch
hardware from inside frame of
breaker as shown.
AKR751008EGBRMOD
& AKR125EGBRMOD
Modification Kit for AKD-8
AKR 75/100 & 125 Large
Frame Breakers

Remote Racking Operator for AKR Breakers
11
4-2 Changing a Small / Large Frame Breaker Door in AKD 8 Switchgear to work with
Remote Racking Operator
AKD-8 Doors
Remote racking
attachment access holes
Kit AKR30S8EG22DR- 800A AKR 22” Wide Breaker Door
Kit AKR30S8EG30DR- 800A AKR 30” Wide Breaker Door
Kit AKR30S8EG22DRDI- 800A AKR 22” Wide Breaker Door with Defeatable Interlock
Kit AKR30S8EG30DRDI- 800A AKR 30” Wide Breaker Door with Defeatable Interlock
Kit AKR30508EG22DR- 800A/1600A AKR 22” Wide Breaker Door
Kit AKR30508EG30DR- 800A/1600A AKR 30” Wide Breaker Door
Kit AKR30508EG22DRDI- 800A/1600A AKR 22” Wide Breaker Door with Defeatable Interlock
Kit AKR30508EG30DRDI- 800A/1600A AKR 30” Wide Breaker Door with Defeatable Interlock
Kit AKR751008EG30DR- 3200A/4000A AKR 30” Wide Breaker Door
Kit AKR751008EG30DRDI- 3200A/4000A AKR 30” Wide Breaker Door with Defeatable Interlock
Kit AKR1258EG38DR- 5000A AKR 38” Wide Breaker Door
Kit AKR1258EG38DRDI- 5000A AKR 38” Wide Breaker Door with Defeatable Interlock

Remote Racking Operator for AKR Breakers
12
4-3 Field Modification to existing Breaker doors.
All existing small and large frame AKR Breaker
doors can be modified in the field to
accommodate the new AKR remote racking
operator. A drilling template kit (CAT#
AKREGDRTEMP) can be provided with (5) drilling
templates (one for each type of breaker door).
The racking flag assemblies (CAT#
AKREGDRMOD) can also be ordered for each
modified breaker door.
Below is a picture demonstrating how to locate
and drill holes in an existing 30S, 75/100 or 125
breaker door. A picture demonstrating how to
locate and drill the holes for a 30/50 breaker
door is located on the next page.
Refer to page 14 for remote racking flag details.
1. Insert bushing of template into
the existing racking hole.
2. Align inside edge of template
with outer ed
g
e of door.
3. Drill (1) 1.75” diameter
hole through the door.
4. Drill (1) 0.251”
diameter hole
through the door.
Figure 7
Door drilling template for AKR 30S, 75/100 and 125 doors
Existing breaker compartment door.

Remote Racking Operator for AKR Breakers
13
1. Place the bottom flange of the template
above the bottom edge of the door cutout. Both
p
ress studs will be on the inside of the cutout.
3. Drill (1) 0.251”
diameter hole
throu
g
h the door.
2. Drill (1) 1.75”
diameter hole
through the door.
Figure 8
Door drilling template for AKR 30/50 doors.
Existing AKR 30/50 breaker door.

Remote Racking Operator for AKR Breakers
14
To
p
of Door
Figure 9
Flag Assembly

Remote Racking Operator for AKR Breakers
15
Aftermarket Solutions available from GE Energy - Industrial Solutions
WavePro/EntelliGuard (Entellisys) Remote Racker GEK-99986
EntelliGuard G Remote Racker DEH-41467
EntelliGuard TU Trip Unit Conversion Kits DET-722
Power Break II into a Power Break I Retrofit Kit DEH-41502
EntelliGuard G AK/AKR Retrofills Coming soon

Remote Racking Operator for AKR Breakers
16
These instructions do not purport to cover all details or variations in equipment or to provide for every possible contingency
to be met in connection with installation, operation or maintenance. Should further information be desired or should
particular problems arise which are not covered sufficiently for the purchaser’s purposes, the matter should be referred to
the General Electric Company.
GE Industrial Systems
41 Woodford Ave.
Plainville, CT 06062
www.geindustrial.com
© 2010 General Electric Company
All Rights Reserved
DEH - 41482
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