Zephyr AK9034AS Installation guide

Use, Care, and Installation Guide
www.zephyronline.com
Model number:
Serial Number:
Date of Purchase:
Sales Dealer:
APR14.0301 © 2014 Zephyr Ventilation
Vortex
AK9028AS
AK9034AS
AK9028AS290
AK9034AS290
READ AND SAVE THESE INSTRUCTIONS

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1
SAFETY NOTICE................................................................. 2-3
LIST OF MATERIALS....................................................... 4
INSTALLATION
Ducting Calculation Sheet....................................... 5
Mounting Height & Clearance................................ 6
Ducting Options........................................................... 7
6SHFL¿FDWLRQV ............................................................... 8
Electrical......................................................................... 9
Custom Hood Preparation & Installation........... 10
Mounting the Liner...................................................... 11
FEATURES & CONTROLS
Slide Controls............................................................... 12
MAINTENANCE
Cleaning & Installing the Filter............................... 13
Ductless Recirculating.............................................. 14
Lights................................................................................ 15
TROUBLESHOOTING................................................................ 16
DIAGRAMS
Fan Curve & Wiring.................................................... 17-18
LIST OF PARTS & ACCESSORIES..................................... 19
Table of Contents

Important Safety Notice
READ AND SAVE THESE INSTRUCTIONS
2
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WARNING
TO REDUCE THE RISK OF FIRE OR ELECTRIC SHOCK, DO NOT USE THIS FAN WITH ANY SOLID-STATE CONTROL DEVICE.
WARNING
TO REDUCE THE RISK OF FIRE ELECTRIC SHOCK, OR INJURY TO PERSONS, OBSERVE THE FOLLOWING:
a. Use this unit only in the manner intended by the manufacturer, if you have questions, contact the manufacturer.
b. Before servicing or cleaning unit, switch power off at service panel and lock panel to prevent power from being switched on accidentally.
When the service disconnecting means cannot be locked, securely fasten a prominent warning device, such as a tag, to the service
panel.
CAUTION
For general ventilating use only. Do not use to exhaust hazardous or explosive materials and vapors. Take care when using cleaning
agents or detergents. Suitable for use in household cooking area.
WARNING
TO REDUCE THE RISK OF RANGE TOP GREASE FIRE:
a. Never leave surface units unattended at high settings. Boilovers cause smoking and greasy spillovers that may ignite. Heat oils slowly
on low or medium settings.
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d. Use proper pan size. Always use cookware appropriate for the size of the surface element.
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f. Use high setting on hood only when necessary.
g. Don’t leave hood unattended when cooking.
h. Always use cookware and utensils appropriate for the type of and amount of food being prepared.
WARNING
TO REDUCE THE RISK OF INJURY TO PERSONS IN THE EVENT OF A RANGE TOP FIRE, OBSERVE THE FOLLOWING:
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b. NEVER PICK UPA FLAMING PAN – You may be burned.
c. DO NOT USE WATER, including wet dishcloths or towels – a violent steam explosion will result.
d. Use an extinguisher ONLY if:
1. You know you have a Class ABC extinguisher, and you already know how to operate it.
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WARNING
TO REDUCE THE RISK OF FIRE, ELECTRIC SHOCK OR INJURY TO PERSONS, OBSERVE THE FOLLOWING:
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,QFOXGLQJ¿UHUDWHGFRQVWUXFWLRQ
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back-drafting. Follow the heating equipment manufacturer’s guideline and safety standards such as those published by the National
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the local code authorities.
c. When cutting or drilling into wall or ceiling, do not damage electrical wiring and other hidden utilities.
d. Ducted fans must always vent to the outdoors.
e. NEVER place a switch where it can be reached from a tub or shower.
f. Make sure the power is off before installing, wiring or maintenancing.

Important Safety Notice
3
WARNING
TO REDUCE THE RISK OF FIRE, USE ONLY METAL DUCTWORK.
CAUTION
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attics, crawl spaces or garages.
OPERATION
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and loose clothing.
The manufacturer declines all responsibility in the event of failure to observe the instructions given here for installation,
maintenance and suitable use of the product. The manufacturer further declines all responsibility for injury due to
negligence and the warranty of the unit automatically expires due to improper maintenance.
*NOTE: Please check www.zephyronline.com for revisions before doing any custom work.
ELECTRICAL REQUIREMENTS
Important:
Observe all governing codes and ordinances.
It is the customer’s responsibility:
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- To assure that the electrical installation is adequate and in conformance with National Electrical Code, ANSI/NFPA 70
latest edition* or CSA standards C22.1-94, Canadian Electrical Code, Part 1 and C22.2 No.0-M91 - latest edition** and
all local codes and ordinances.
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ground path is adequate.
Do not ground to a gas pipe.
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Do not have a fuse in the neutral or ground circuit.
*National Fire Protection Association Batterymarch Park, Quincy, Massachusetts 02269
** CSA International 8501 East Pleasant Valley Road, Cleveland, Ohio 44131-5575
This appliance requires a 120V 60Hz electrical supply and connected to an individual properly grounded branch circuit
protected by a 15 or 20 ampere circuit breaker or time delay fuse. Wiring must be 2 wire with ground. Please also refer to
Electrical Diagram on product.
AK9028AS / AK9034AS - Max. 315W @ 3 Amps
AK9028AS290 / AK9034AS290 - Max. 130W @ 1.5 Amps
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and install appropriate connector if necessary.

List of Materials
4
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PARTS SUPPLIED
1 - One piece liner
1 - Adjustable front panel
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1 - Hardware package
HARDWARE PACKAGE CONTENTS
PARTS NOT SUPPLIED
- Ducting, conduit and all installation tools
- Cable connector (if required by local codes)
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Light Bulb Removal
Suction Cup (1)
Wire Caps (3)
#8 x 1/2” (8)

5
Installation – Ducting Calculation Sheet
Duct pieces To t a l
Equivalent number
length x used =
3-1/ 4” x 10”
Rect.,
straight
1 Ft. x ( ) = Ft.
7”-10” Round,
straight
1 Ft. x ( ) = Ft.
3-1/ 4” x 10”
Rect.900
elbow
15 Ft. x ( ) = Ft.
3-1/ 4” x 10”
Rect.450
elbow
9 Ft. x ( ) = Ft.
3-1/ 4” x 10”
Rect.900
flat elbow
24 Ft. x ( ) = Ft.
3-1/ 4” x 10”
Rect.
wall cap
with damper
30 Ft. x ( ) = Ft.
3-1/ 4” x 10”
Rect.to
6” round
transition
5 Ft. x ( ) = Ft.
3-1/ 4” x 10”
Rect.to
6” round
transition
900elbow
20 Ft. x ( ) = Ft.
6” Round,
900elbow
15 Ft. x ( ) = Ft.
6” Round,
450elbow
9 Ft. x ( ) = Ft.
Ft.
6” Round,
straight
1 Ft. x ( ) = Ft.
Subtotal column 1 =
Duct pieces To t a l
Equivalent number
length x used =
6” Round
wall cap
with damper
30 Ft. x ( ) = Ft.
Round
wall cap
with damper
30 Ft. x ( ) = Ft.
7” - 10”
Round,
900elbow
15 Ft. x ( ) = Ft.
7” - 10”
7” - 10”
Round,
450elbow
9 Ft. x ( ) = Ft.
Ft.
Ft.
Ft.
6” Round,
roof cap
30 Ft. x ( ) = Ft.
7” - 10”
Round,
roof cap
30 Ft. x ( ) = Ft.
Subtotal column 2 =
Subtotal column 1 =
Total ductwork =
6” round to
3-1/ 4” x 10”
rect.
transition
1 Ft. x ( ) = Ft.
6” round to
3-1/ 4” x 10”
rect.
transition
900elbow
16 Ft. x ( ) = Ft.
7” round to
3 1/ 4” x 10”
rect.
transition
8 Ft. x ( ) = Ft.
7” round to
3-1/ 4” x 10”
rect.
transition
900elbow
23 Ft. x ( ) = Ft.
Maximum Duct Length: For satisfactory air movement, the
total duct length should not exceed 100 equivalent feet.

Installation – Mounting Height & Clearance
6
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DUCTING
A minimum of 6” round duct must be used to
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Always use rigid type metal ducts only. Flexible
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available duct run when using elbows, transitions
and caps.
ALWAYS, when possible, reduce the number or
transitions and turns. If long duct run is required,
increase duct size.
If turns or transitions are required; install as far
away from insert duct output and as far apart,
between the two as possible.
Minimum mount height between range top to
cabinet bottom should be no less than 26”.
Maximum mount height should be no higher than
36”.
It is important to install the liner at the proper
mounting height. Liners mounted too low could
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mounted too high will be hard to reach and will
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If available, also refer range manufacturer’s height
clearance requirements and recommended liner
mounting height above range.
Vertical Ducting:
6” round minimum
Horizontal Ducting:
N/A
DAMAGE-SHIPMENT / INSTALLATION:
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installation.
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unit to the store in which it was bought for
repair or replacement.
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or replacement is the responsibility of the
customer.
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WKDQWKHFXVWRPHUUHSDLURIUHSODFHPHQWPXVW
be made by arrangement between customer
and installer.
26” min.
36” max.
36”

7
WARNING FIRE HAZARD
NEVER exhaust air or terminate duct work into spaces between walls, crawl spaces, ceiling, attics or garages.
All exhaust must be ducted to the outside.
Use metal ductwork only.
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Some Ducting Options
Installation – Ducting Options
side wall cap
w/ gravity damper
side wall cap
w/ gravity dampe
r
Soffit or crawl space
Roof Pitch w/
Flashing & Cap

8
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Installation – 6SHFL¿FDWLRQV
3/4 View
Top View
Back View
6”
12-
5/16
”
1
7-1/2
”
-
20-1/
2
”
2
8
-
3/8
”
*,
34-
3/8
”*
2-
1/16
”
2-
5/8
”
10-
1/4
”
3/8”
C/L
C/L
10- 5/8 ”
26- 9/16 ”
4- 1/8 ”
5-
3/8
”
17-
1/2
”
10-
5/16
”1-
7/16
”
adjust
able
d
ep
t
h
*dimensions do not include 3/8”
wide flange around the liner

9
ELECTRICAL
WARNING
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how and background.
For personal safety, remove house fuse or open circuit breaker before beginning installation. Do not use
extension cord or adapter plug with this appliance.
Follow national electrical codes or prevailing local codes and ordinances.
Electrical Supply:
This appliance requires a 120V 60Hz electrical supply, and connected to an individual, properly grounded
branch circuit, protected by a 15 or 20 ampere circuit breaker or time delay fuse. Wiring must be 2 wire w/
ground. Please also refer Electrical Diagram labeled on product.
Cable Lock:
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and codes, purchase and install appropriate connector if necessary.
Installation – Electrical
Cable Lock

10
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Installation – Custom Hood Preparation & Installation
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SURWHFWLYH¿OPSULRUWRLQVWDOODWLRQ8VHFDXWLRQ
during installation to prevent scratches or damage
to the stainless steel.
2. Prepare custom hood enclosure by following the
dimensions in FIG. 1.
3. Install liner into custom hood. FIG. 2, Page 11.
WARNING: Make sure the surface you are securing the
liner to is capable of holding the weight of AK90. Failure
to do so may cause personal injury or damage to cooking
surface or counter. Wood blocking may need to be added
to cabinet base if additional support is needed.
4. Secure front panel to custom hood. FIG. 3, Page 11
5. Finalize electrical and duct work. Seal duct work
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Note: If access to the top of the liner is not available
after installation, duct work and electrical connection
may need to be installed prior to installing the liner.
6. Power on the liner, check for leaks around duct tape
and test for proper operation.
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CAUTION: At least two installers are
required due to the weight and size of the
hood.
!
FIG. 1
If possible, power up and test all functions prior to installation.
C
A
D
E
2 - 1/ 1 6 ”
B
cut-out
Plywood Base
3/4''
Side Panel Thickness:
Recommended
3/8” Wide Flange
17 1/2” - 20 1/2” 17 1/8” - 20 1/8”
Without Backboard With Backboard**
Inside Depth* (B)
Inside
Width* (A)
Custom Hood
Exterior WidthModel
30 inches
36 inches
AK9028AS
AK9034AS
AK9028AS
AK9034AS
28 1/2”
34 1/2”
Without Backboard With Backboard**
Model Cut-Out
Depth (D)
26-5/8”10-1/2”
Cut-Out
Width (C)
Rear Base
Depth
1-3/8”1”
(E)
*Dimension does not include 3/8” wide flange around liner.
**Assumes backboard thickness of 3/8”
FIG. 1

11
FIG. 2
FIG. 3
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stainless steel screws. FIG. 2.
WARNING: Make sure the surface you are securing the liner to is capable of holding the
weight of AK90. Failure to do so may cause personal injury or damage to cooking surface
or counter. Wood blocking may need to be added to custom hood base if additional
support is needed.
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3. Lift front panel up and slide into the nose of the custom hood base. The tape
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ÀXVKZLWKWKHOLQHUERWWRPÀDQJH),*
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5. Return to Page 10, Step 5 to complete installation.
Installation – Mounting the Liner
FIG. 3-3
1
3
2
flange
liner flange

12
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0 I II III
Blower On/Off Speed Selection
1
Lights Bright/Dim/Off
2
0 I II
Features & Controls – Slide Controls
BLOWER ON/OFF/SPEED SELECTION
0 is off, I is low speed, II is medium speed and III is high speed.
LIGHTS BRIGHT/DIM/OFF
0 is off, I is dim, and II is bright.
1
2

13
SURFACE MAINTENANCE:
Clean periodically with hot soapy water and clean cotton cloth. Do not use corrosive or abrasive detergent, or steel wool/
scoring pads which will scratch and damage surface. Do not use products containing chlorine bleach or orange cleaners.
For heavier soil use liquid degreaser.
After cleaning, you may use non-abrasive stainless steel polish/ cleaners, to polish and buff out the stainless luster and
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&OHDQLQJWKH%DIÀH)LOWHU
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required to be cleaned every 30 days or more often depending on cooking habits.
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Part No. Qty. to Order
50210016 1
3
2
1
Maintenance – Cleaning & Installing the Filter
NOTE: If your liner is setup for ductless recirculating, make
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FIG. 4

Maintenance – Ductless Recirculating
14
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DUCTLESS RECIRCULATING (OPTION)
Ductless recirculating is intended for applications where an exhaust duct work is not possible to be installed.
When converted, the one piece liner functions in air “purifying” mode rather than exhausting the air. Fumes
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back into the kitchen.
We recommend to always exhaust air outside of the home by employing existing or installing new duct work,
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possible should you use the liner in recirculating mode.
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Purchase recirculating kit as follows.
Part No. Qty. to Order
ZRC-9000 1
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usage of 1 hour a day.
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Part No. Qty. to Order
Z0F-C090 1
bae lter frame
charcoal
lter
Return Air Vent
top of cabinet
For detailed installation instructions please refer to manual included with recirculating kit.

15
REPLACING LIGHT BULBS
CAUTION: Light bulb becomes extremely hot when turned on.
DO NOT touch bulb until switched off and cooled. Touching hot bulbs could cause serious burns.
Make sure all power is turned off and bulbs are not hot.
Remove by turning bulb counter clockwise. Note: Bulb does not unscrew; it turns 60 degrees, stops and
falls out.
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latex glove and turn counter clockwise.
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For Zephyr part numbers please turn to page 19 of the manual.
Bottom View
Maintenance – Lights

Troubleshooting
16
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TROUBLESHOOTING PROCEDURES FOR VORTEX
Issue Cause What to do
After installation,
the unit doesn’t
work.
1. The power source is not turned ON. 1. Make sure the circuit breaker and the unit’s
power is ON.
2. The power line and the cable locking connector
is not connecting properly. 2. Check the power connection with the unit is connected properly.
3. The switch wirings are disconnected. 3. Make sure the wirings at the switch are
connected properly.
4. The switch is defective. 4. Change the switch.
Light works, but
blower is not
turning.
1. The blower is defective, possible seized. 1. Change the blower.
2. The thermally protected system detects if the
blower is too hot to operate and shuts the blower
down.
2. The blower will function properly after the
thermally protected system cools down.
3. Blower molex plug pin is not making contact. 3. Disconnect the blower molex plug, check pins
inside plug to see if one is pushed inside the
plug too far. Reseat pin if needed.
4. Damaged capacitor. 4. Change the capacitor.
The unit is
vibrating. 1. The blower is not secure in place. 1. Tighten the blower in place.
2. Damaged blower wheel. 2. Change the blower.
3. The hood is not secured in place. 3. Check the installation of the hood.
The unit is
whistling. 7KH¿OWHULVQRWLQWKHFRUUHFWSRVLWLRQ &KDQJHWKHSRVLWLRQRIWKH¿OWHU
2. The duct pipe connections are not connected
properly. 2. Check the duct pipe connections to be sure all are connections are sealed properly.
The blower is
working, but the
lights are not.
1. Defective halogen bulb. 1. Change the halogen bulb.
2. The light bulb is loose. 2. Tighten the light bulb.
3. The light bulb plug is disconnected. 3. Connect the light bulb plug.
The hood is
not venting out
properly.
1. The hood might be hanging to high from the
cook top. 1. Adjust the distance between the cook top and the bottom of the hood within 26” to 36” range.
2. The wind from the opened windows or opened
doors in the surrounding area are affecting the
ventilation of the hood.
2. Close all the windows and doors to eliminate
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3. Blocking in the duct opening or duct work. 3. Remove all the blocking from the duct work or
duct opening.
4. The direction of duct opening is against the wind. 4. Adjust the duct opening direction.
5. Using the wrong size of ducting. 5. Change the ducting to at least 6” or higher.
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vibrating.  0HWDO¿OWHULVORRVH  &KDQJHWKHPHWDO¿OWHU
2. Spring clip is broken. 2. Change the spring clip.

Diagrams – Fan Curve & Wiring
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
1.10
1.20
1.30
1.40
1.50
1.60
1.70
1.80
1.90
2.00
2.10
2.20
2.30
2.40
2.50
2.60
2.70
2.80
0 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500 525 550 575 600 625 650 675 700 725 750
Pressure (inAq)
Flow rate (CFM)
Blower Fan Curve
Model: AK90 (Vortex)
AC Input: 120V, 60Hz
Outlet Diameter: 6in
3A
17

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Diagrams – Fan Curve & Wiring
025
0.30
0.35
0.40
0.45
0.50
0.55
0.60
0.65
0.70
0.75
0.80
Pressure (inAq)
Blower Fan Curve
Model: AK90-290 (Vortex)
AC input: 120V - 60Hz
Outlet Diameter: 6in
0.00
0.05
0.10
0.15
0.20
0
.
25
0 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400
Flow rate (CFM)
1.5A
18