Retrofill Doors
Assemblies for AKD-5,
AKD-6, and AKD-8
Retrofit doors for the EntelliGuard® Retrofill can be ordered as required, depending on door
size and if you want door cutouts for accommodating lamps and ammeters.
imagination at work
Table of Contents
Related Publications ...................................................................................................................................................................................... 3
Doors, Retrofit Ordering and Replacement ............................................................................................................................................... 3
27-Inch Door (AKD5, AK50) .................................................................................................................................................................................................... 8
Replace AKD5 Door ......................................................................................................................................................................................10
Modify Existing Door .................................................................................................................................................................................... 10
AKD-6, AKR Retrofit Door ............................................................................................................................................................................10
22-Inch Door (AKD6) ...................................................................................................................................................................................................................... 11
27-inch Door Sizes (AKD6) .......................................................................................................................................................................................................... 13
Replacing AKD6 Door Assembly .............................................................................................................................................................................................. 15
Modifying Existing Door ....................................................................................................................................................................................................... 15
AKD-8, AKR30S, AKR30H, AKR 30/50 Retrofit Door Assemblies ...........................................................................................................15
22-Inch and 30-Inch RH AKD8 ................................................................................................................................................................................................. 16
Replacing AKD8 Door Assembly .............................................................................................................................................................................................. 21
Modifying Existing Door ....................................................................................................................................................................................................... 21
AK25 DOOR ASSY, 20” ........................................................................................................................................................................................................... 26
AK25 DOOR ASSY, 20” WITH LIGHT ................................................................................................................................................................................. 27
AK25 DOOR ASSY, 20” RH .................................................................................................................................................................................................... 28
AK25 DOOR ASSY, 22” ........................................................................................................................................................................................................... 29
AK25 DOOR 22” ASSY ............................................................................................................................................................................................................ 30
AK25 DOOR ASSY- 27”, 30”, 38” ........................................................................................................................................................................................ 31
AK25 DOOR ASSY, 27” WITH LIGHT ................................................................................................................................................................................. 32
AK25 DOOR ASSY, 27” WITH LIGHT ................................................................................................................................................................................. 33
Retrofill Doors Assemblies for AKD-5, AKD-6, and AKD-8
AK50 DOOR ASSY- 27”, 30”,38”.......................................................................................................................................................................................... 34
AK50 DOOR ASSY, 20” WITH LIGHT ................................................................................................................................................................................. 35
AK50 DOOR ASSY-27”, RH ................................................................................................................................................................................................... 36
AK50 DOOR ASSY- 27”, 30”,38”.......................................................................................................................................................................................... 37
AK50 DOOR ASSY, 20” WITH LIGHT ................................................................................................................................................................................. 38
AK50 DOOR ASSY-27”, RH ................................................................................................................................................................................................... 39
AKD6 DOOR ASSY, 22” ........................................................................................................................................................................................................... 40
AKD6 DOOR ASSY, 22” WITH LIGHT ................................................................................................................................................................................ 41
Door Assembly of AKD6 ....................................................................................................................................................................................................... 42
AKD6 27”,30” & 38” DOOR ASSY ....................................................................................................................................................................................... 43
AKD6 27” DOOR ASSY WITH LIGHTS............................................................................................................................................................................... 44
AKD6 27 & 30” DOOR ASSY ................................................................................................................................................................................................. 45
• Turn off all power to switchgear. Tagout
and lockout main source, up-stream or
main breaker.
• Failure to comply with these instructions
will result in death or serious injury from
severe burns caused by arc flashing that
has exceedingly high temperatures.
• Always wear personal protection equipment
according to OSHA standards and appropriate
to the severity of potential burns.
• Ensure only qualified personnel install, operate, service, and maintain all electrical equipment.
It takes about 5 to 15 minutes to install the retrofill door(s) in the switchgear, but does not include the 20-minute
timing claimed for the roll-in replacement.
Retrofill Doors Assemblies for AKD-5, AKD-6, and AKD-8
3
DEH-41563 02/12
AKD-5, AK25 Retrofit Door
Retrofit doors for the can be ordered as required, depending on door size and if you want door cutouts for
accommodating lamps and ammeters (Figure 1 and Figure 2). In this section, the particular wireframe figures
feature different door sizes. Table 1 lets you specify a door type. It can be ordered by catalog number by
referring to the last column in the table. Some doors allow cutouts for lamps and/or ammeters; some do not.
All the doors in Table 1 are right-hand doors.
20-Inch Door (AKD5, AK25)
Figure 1. AK25 (20-inch door assembly) with and without Cutouts for Lights
Figure 2. AK25 (20-inch door assembly) with Cutouts for Lights and Accessories
DEH-41563 02/12
Retrofill Doors Assemblies for AKD-5, AKD-6, and AKD-8
4
22-Inch Door (AKD5, AK25)
Figure 3 displays 22-inch door assemblies, with and without cutouts for lights. The next figure, Figure 4 displays
cutouts for both lights and accessories.
Figure 3. AK25 (22-inch door assembly) with and without Cutouts for Lights
Figure 4. AK25 (22-inch door assembly) with Cutouts for Lights and Accessories
Retrofill Doors Assemblies for AKD-5, AKD-6, and AKD-8
5
DEH-41563 02/12
27-Inch Door (AKD5, AK25)
Figure 5 displays 27-inch door assemblies, with and without cutouts for lights. The next figure, Figure 6, displays
cutouts for both lights and accessories.
Figure 5. AK25 (27-inch door assembly) with and without Cutouts for Lights
Figure 6. AK25 (27-inch door assembly) with Cutouts for
Lights and Accessories
DEH-41563 02/12
Retrofill Doors Assemblies for AKD-5, AKD-6, and AKD-8
6
Table 1. Replacement Door Categories (TOP LEVEL)
Available Stack Width
(in inches)
2022273038
Type
Door
Width
(in inches)
Door
Bump-out
(in inches)
Description
AK25 DOOR
ASSY
AK25 DOOR
ASSY
AK25 DOOR
ASSY
AK25 DOOR
ASSY
AK25 DOOR
ASSY
AK25 DOOR
ASSY
AK25 DOOR
ASSY
AK25 DOOR
ASSY
Cutout Options
Breaker
Type
AK25AKD5YESYES YES YESRH27YES—3.7
AK25AKD5YESYESRH20YES—3.7
AK25AKD5YESYESRH22YES—3.7
AK25AKD5YESYESRH20YES—3.7
AK25AKD5YESYESRH22YES—3.7
AK25AKD5YESYESRH22YES—3.7
AK25AKD5YESYES YES YESRH27YES—3.7
AK25AKD5YESYES YES YESRH27YES—3.7
LVS
Fascia
Cutout
Only
Lamps
Only
Lamps +
Amme-
ter
Assy. DWG—27” RH AK25 Retrofill (Sheet 1)
Sheet 1 of Drawing 10106255 is shown below. Sheet 2 of this drawing immediately follows Sheet 1.
Refer to BOM 10106255G1.
GCAT #
10106255G1
10107429G1
10108047G1
10108345G1
10108347G1
10108376G1
10108380G1
10108383G1
DWG 1 (Sheet 1). 10106255 Door Assembly—27” RH AK25 Retrofill
Retrofill Doors Assemblies for AKD-5, AKD-6, and AKD-8
7
DEH-41563 02/12
Assy. DWG—27” RH AK25 Retrofill (Sheet 2)
DWG 1 (Sheet 2). 10106255: Door Assembly—27” RH AK25 Retrofill
AKD-5, AK50 Retrofit Door
27-Inch Door (AKD5, AK50)
Retrofit doors for the can be ordered as required, depending on door size and if you want door cutouts for
accommodating lamps and ammeters (Figure 7 and Figure 8). In this section, the particular wireframe figures
feature different door sizes. Table 2 lets you select a specific door type. It can be ordered by catalog number
by referring to the last column in the table. Two doors allow cutouts for lamps and/or ammeters; one does not
allow any cutouts. All the doors in Table 2 are right-hand doors.
DEH-41563 02/12
Retrofill Doors Assemblies for AKD-5, AKD-6, and AKD-8
8
Figure 7. AK50 (27-inch door assembly) with and without Cutouts for Lights
Figure 8. AK50 (27-inch door assembly) with
Cutouts for Lights and Accessories
Table 2. Replacement Door Categories (TOP LEVEL)
Cutout Options
Description
AK50 DOOR
ASSY
AK50 DOOR
ASSY
AK50 DOOR
ASSY
Retrofill Doors Assemblies for AKD-5, AKD-6, and AKD-8
9
Breaker
Type
AK50AKD5YESYES YES YESRH27No
AK50AKD5YESYES YES YESRH27No
AK50AKD5YESYES YES YESRH27No
LVS
Fascia
Cutout
Only
Lamps
Only
Lamps +
Amme-
ter
Available Stack Width
(in inches)
2022273038
Type
Door
Width
(in inches)
Door
Bump-out
(in inches)
GCAT #
10106248G1
10108355G1
10108363G1
DEH-41563 02/12
Replace AKD5 Door
Sequence of replacement of door assemblies will remain the same for all AKD5 type doors.
1. De-energize/switch off the LVS section that is to be retrofitted.
2. Open the compartment door that is to be retrofitted.
3. Rack out the existing legacy AK/AKR breaker from the LVS.
4. Keep the door open for accessing the door mounting hinges. These are placed on the right side wall of the
moving frame in the LVS compartment.
5. The door hinge is mounted via 2/3-mounting pins that hold the door in place.
6. Lift the pin out of the hinge joint. This allows access for removing the old door from the LVS compartment.
7. Unpack the new door assembly and mount it on the door mounting hinges. These are located at the right
side of the moving frame.
8. Replace the hinge pins and secure the joints.
9. Insert the new retrofitted EntelliGuard R Retrofill circuit breaker into the compartment and slide the breaker into
the disconnected condition.
10. Close the new door and secure it to the compartment.
11. Rack-in the new retrofitted EntelliGuard R Retrofill in.
Modify Existing Door
If customer doesn’t want to buy a new door, the customer can modify the existing door:
1. Remove the legacy door assembly from the LVS section.
2. Modify the door cut out as per the new door cutout template.
3. Check the through-door racking with the new door assembly.
AKD-6, AKR Retrofit Door
Retrofit doors for the can be ordered as required, depending on door size and if you want door cutouts for accommodating lamps and ammeters. Table 3 lets you select a specific door type (Figure 9 and Figure 10). In this section,
the particular wireframe figures different door sizes. It can be ordered by catalog number by referring to the last
column in the table. Some doors allow cutouts for lamps and/or ammeters; some do not. All the doors in Table 3 are
right-hand doors.
DEH-41563 02/12
Retrofill Doors Assemblies for AKD-5, AKD-6, and AKD-8
10
22-Inch Door (AKD6)
Figure 9. AKD6 (22-inch door assembly) with and without Cutouts for Lights
Figure 10. AKD6 (22-inch door assembly) with
Cutouts for Lights and Accessories
Retrofill Doors Assemblies for AKD-5, AKD-6, and AKD-8
11
DEH-41563 02/12
Assy. DWG—22” RH AKD6 Retrofill (Sheet 1)
Sheet 1 of Drawing 10108439 is shown below. Sheet 2 of this drawing immediately follows Sheet 1. Refer to
BOM 10108439G1.
For the AKD6, Figure 11 displays the 27-inch door assembly with and without cutouts for lights. Figure 12 shows
cutouts or punch-outs for the same door assembly.
Figure 11. AKD6 (27-inch door assembly) with and without Cutouts for Lights
Retrofill Doors Assemblies for AKD-5, AKD-6, and AKD-8
13
DEH-41563 02/12
Figure 12. AKD6 (27-inch door assembly with
Cutouts for Lights and Accessories
Table 3. Replacement Door Categories (TOP LEVEL)
Description
AKD6 DOOR
ASSY
AKD6 DOOR
ASSY
AKD6 DOOR
ASSY
AKD6 DOOR
ASSY
AKD6 DOOR
ASSY
AKD6 DOOR
ASSY
Cutout Options
Breaker
Type
AKRAKD6YESYESRH22No
AKRAKD6YESYESRH22No
AKRAKD6YESYESRH22No
AKRAKD6YESYES YES YESRH27No
AKRAKD6YESYES YES YESRH27No
AKRAKD6YESYES YES YESRH27No
LVS
Fascia
Cutout
Only
Lamps
Only
Lamps +
Amme-
ter
Available Stack Width
(in inches)
2022273038
Type
Door
Width
(in inches)
Bump-out
(in inches)
Door
GCAT #
10107469G1
10108074G1
10108439G1
10108447G1
10108462G1
10108469G1
DEH-41563 02/12
Retrofill Doors Assemblies for AKD-5, AKD-6, and AKD-8
14
Replacing AKD6 Door Assembly
Sequence of replacement of door assemblies will remain the same for all AKD6 type doors.
1. De-energize/switch off the LVS section that is to be retrofitted.
2. Open the compartment door that is to be retrofitted.
3. Rack out the existing legacy AK/AKR breaker from the LVS.
4. Keep the door open for accessing the door mounting hinges. These are placed on the right side wall of the
moving frame in the LVS compartment.
5. The door hinge is mounted via 2/3-mounting pins that hold the door in place. [What does the “2/3” mean: size,
inches, type, etc.?] [How many pins are there per door?]
6. Lift the pin out of the hinge joint. This will provide access for removing the old door from the LVS compartment.
7. Unpack the new door assembly and mount it on the door mounting hinges. These are placed [found?] [or are
they already installed there?] at the right side of the moving frame.
8. Replace the hinge pins and secure the joints.
9. Insert the new retrofitted EntelliGuard R Retrofill circuit breaker into the compartment and slide the breaker into
the disconnected condition.
10. Close the new door and secure it to the compartment.
11. Rack-in the new retrofitted EntelliGuard R Retrofill in. [OK, what do I do with the old door? Discard it—salvage it
for something else?]
Modifying Existing Door
If customer doesn’t want to buy a new door, the customer can modify the existing door:
1. Remove the legacy door assembly from the LVS section.
2. Modify the door cut out as per the new door cutout template.
3. Check the through-door racking with the new door assembly.
AKD-8, AKR30S, AKR30H, AKR 30/50 Retrofit Door Assemblies
Retrofit doors for the can be ordered as required, depending on door size and if you want door cutouts for
accommodating lamps and ammeters (Figure 13, Figure 14, and Figure 15). Table 4 lets you select a specific door
type. It can be ordered by catalog number by referring to the last column in the table. Some doors allow cutouts for
lamps and/or ammeters; some do not. All the doors in Table 4 are right-hand doors.
Retrofill Doors Assemblies for AKD-5, AKD-6, and AKD-8
15
DEH-41563 02/12
22-Inch and 30-Inch RH AKD8
Figure 13. AKD8 (22-inch door assembly)
Figure 14. AKD8 (30-inch door assembly)
Figure 15. AKD8 AKR30S (30-inch door assembly)
DEH-41563 02/12
Retrofill Doors Assemblies for AKD-5, AKD-6, and AKD-8
16
Table 4. Replacement Door Categories (TOP LEVEL)
Available Stack Width
(in inches)
2022273038
Type
Door
Width
(in inches)
Door
Bump-out
(in inches)
10108089G1
10108090G1
10106239G1
10108088G1
Description
AKR30S
DOOR ASSY
AKR30S 30"
DOOR ASSY
DOOR
ASSY, AKD8
AKR30H
AKD8
AKR30/50 30"
DOOR ASSY
Breaker
Type
AKR
AKR
AKR
AKR
LVS
AKD8—
AKR30S
AKD8—
AKR30S
AKD8—
Regular
AKD8—
Regular
Cutout Options
Fascia
Cutout
Only
YESYESRH22YES—2.95
YESYESRH30YES—2.95
YESYESRH22No
YESYESRH30No
Lamps
Only
Lamps +
Amme-
ter
Assy. DWG—30” RH AKR30S Retrofill (Sheet 1)
Sheet 1 of Drawing 10108090 is shown below. Sheet 2 of this drawing immediately follows Sheet 1. Refer to
BOM 10108090G1.
Retrofill Doors Assemblies for AKD-5, AKD-6, and AKD-8
20
Replacing AKD8 Door Assembly
Figure 16 is an example of an AKD-8 installed with a new, retrofill door for the newly installed retrofill breaker. (Note
that the figure shows that a motor can power the racking-in of the retrofill breaker.)
Sequence of replacement of door assemblies will remain
the same for all AKD8 type doors.
1. De-energize/switch off the LVS section that is to be
retrofitted.
2. Open the compartment door that is to be retrofitted.
3. Rack out the existing legacy AK/AKR breaker from
the LVS
4. Keep the door open for accessing the door
mounting pads placed on the right side wall in
the LVS compartment.
5. Loosen the screws holding the mounting pads to
the compartment frame.
6. Note that this will provide access for removing the
old door from the LVS compartment.
7. Unpack the new door assembly and mount it on the
compartment and secure via placing the pads and
tightening the screws.
8. Insert the new retrofitted EntelliGuard R Retrofill circuit breaker into the compartment and slide the breaker into
the disconnected condition.
Figure 16. New Doors Assembled on AKD-8—A 30”-Door
9. Close the new door and secure it to the compartment.
10. Rack-in the new retrofitted EntelliGuard R Retrofill circuit breaker in.
Modifying Existing Door
If customer doesn’t want to buy a new door, the customer can modify the existing door:
1. Remove the legacy door assembly from the LVS section.
2. Modify the door cut out as per the new door cutout template.
3. Check the through-door racking with the new door assembly.
Retrofill Doors Assemblies for AKD-5, AKD-6, and AKD-8
21
DEH-41563 02/12
Figure 17 shows a legacy breaker in the cabinet with the old doors still attached. Figure 18 shows the retrofill breaker,
racked in a compartment, waiting for a retrofill door to be installed. The other three compartment doors have the
retrofill doors already, but no retrofill breakers yet.
Figure 18. AKR with New DoorFigure 17. Legacy AK with Old Door
DEH-41563 02/12
Retrofill Doors Assemblies for AKD-5, AKD-6, and AKD-8
22
Retrofill Escutcheon Kit—Spare
Table 5 displays some kit options.
Table 5. Escutcheon Options Kit
Fascia Cutout Only
No
Lamps Only
Description
Retrofill Escutcheon
Kit—Spare
Escutcheon Kit
Drawout
Breaker
Type
AK25AKD5YESYESYESYESYES
AKRAKD6N/AYESYESYESYES
AKRAKD8—AKR30SN/AYESYESYESYES
AKRAKD8 RegularN/AYESYESYESYES
AK50AKD5N/AN/AYESYESYES
LVS
Cutouts
BOM (Bill of Materials)
BOM 10106255G1
10106255G1
Seq#Item NumberDescriptionQuantity
010106255PV1PCVU0
010106255PV1PCVU0
110106246G1AK25 DOOR WELDMENT-27"1
210107389G1LATCH ASSEMBLY1
310108592G1HANDLE ASSY 1
4N22P21008B6BOLT,STEEL HEX 1/4-20X1/21
510107388P1DOOR INTERLOCK CATCH PLATE1
675V100058P104RIVET POP2
710106236P1ESCUTCHEON SEAL1
810106237P1ESCUTCHEON, AK-25 1
910100923P2CERRATED BELLEVILLE WASHER M312
1010102274P1POZIDRIV CROSS RECESD PAN HEAD12
1110108739P1DOOR LABEL, RETROFILL0
1110108749P1LABELS, BLANK DOOR1
1210108741P1CAUTION LABEL, RETROFILL1
Lamps +
Ammeter
Available Stack Width
(in inches)
2022273038
GCAT #
10109607G1
10102167G1
Retrofill Doors Assemblies for AKD-5, AKD-6, and AKD-8
23
DEH-41563 02/12
BOM 10108088G1
10108088G1
Seq#Item NumberDescriptionQuantity
010108088PV1PCVU0
110106244P1DOOR, AKD8-30"1
210106237P1ESCUTCHEON, AK-25 1
310106444P1ESCUTCHEON SEAL1
410106452P1GASKET SPT, SIDES. AKD82
510106453P1GASKET SPT, TOP & BTM2
610100923P2CERRATED BELLEVILLE WASHER M312
710102274P1POZIDRIV CROSS RECESD PAN HEAD12
875C149385P014BRACKET1
975V100058P104RIVET POP2
1075C149310G002HINGE PIN1
11N84P16006B6SCREW,STEEL MACH 10-32X3/84
120317A8780P001HANDLE-NONLOCKING1
1375C149310G001HINGEPIN1
1410108739P1DOOR LABEL, RETROFILL0
1410108749P1LABELS, BLANK DOOR1
1510108741P1CAUTION LABEL, RETROFILL1
BOM 10108439G1
10108439G1
Seq#Item NumberDescriptionQuantity
010108439PV1PICVU0
110108438G1AKD6 DOOR WELDMENT, 221
210108590G1LATCH ASSY AKD6 RETROFILL1
310108592G1HANDLE ASSY 1
4N22P21008B6BOLT,STEEL HEX 1/4-20X1/21
510103363P1ESCUTCHEON SEAL1
610103362P1ESCUTCHEON1
710100923P2CERRATED BELLEVILLE WASHER M312
810102274P1POZIDRIV CROSS RECESD PAN HEAD11
910108739P1DOOR LABEL, RETROFILL0
910108749P1LABELS, BLANK DOOR1
1010108741P1CAUTION LABEL, RETROFILL1
DEH-41563 02/12
Retrofill Doors Assemblies for AKD-5, AKD-6, and AKD-8
24
BOM 10108090G1
10108090G1
Seq#Item NumberDescriptionQuantity
010108090PV1PCVU0
110103266P1Door, AKR30S- 30"1
210106237P1ESCUTCHEON, AK-25 1
310106444P1ESCUTCHEON SEAL1
410106452P1GASKET SPT, SIDES. AKD82
510106453P1GASKET SPT, TOP & BTM2
610100923P2CERRATED BELLEVILLE WASHER M312
710102274P1POZIDRIV CROSS RECESD PAN HEAD12
875C149385P014BRACKET1
975V100058P104RIVET POP2
1075C149310G002HINGE PIN1
11N84P16006B6SCREW,STEEL MACH 10-32X3/84
120317A8780P001HANDLE-NONLOCKING1
1375C149310G001HINGEPIN1
1410108739P1DOOR LABEL, RETROFILL0
1410108749P1LABELS, BLANK DOOR1
1510108741P1CAUTION LABEL, RETROFILL1
BOM 10108361G1
10108361G1
Seq#Item NumberDescriptionQuantity
010108361PV1PICVU0
110108276P1AK50 DOOR WITH LIGHTS1
210108582P1HOLDER3
310108597P1STUD AKD5 & AKD6 RETROFILL2
410108606P1STUD AK50 -AKD5 & AKD61
510108401P1COVER FOR AKD5 AK50 DOOR1
Retrofill Doors Assemblies for AKD-5, AKD-6, and AKD-8
25
DEH-41563 02/12
Comprehensive BOM: All Levels
AKD-5 AK25
AK25 DOOR ASSY, 20”
Level
GCAT10108345G1AK25 DOOR ASSY, 20"1EA (each)
__2010108341PV11PICVU0EA (each)Phantom
__2110108338P11AK25 DOOR, 20"1EA (each)Phantom
___3CDE22557013GA, CR, B8A3A33.01LB (pound)Raw Material