NOVENCO ZERAX AZL-AZN-AZW Instruction Manual

Pure competence in air.
ENGLISH 922950-0
NOVENCO® ZERAX® FAN TYPES
AZL-AZN-AZW
INSTALLATION AND
MAINTENANCE

Novenco ZerAx axial fan types AZL-AZN-AZW – Installation and maintenance 2 of 30
Important
This document is provided ’as is’. Novenco Building & Industry A/S reserves the right to
changes without further notice due to continuous product development.
The fans are designed for continuous operation. The following kinds of operation may cause
fatigue break in the rotors and endanger people.
•Operation in stall area
• Operation with pulsating counter pressure – called pump mode
•Operation with exceedingly starts and stops
If in doubt, Novenco should be contacted to assess the suitability of the fans.
Copyright © 2009 - 2022, Novenco Building & Industry A/S. All rights are reserved.
Document revision no.: MU16068 0822
Document item no.: 922950-0
Patents and trademarks
Novenco®, , and are registered trademarks of Novenco Marine & Offshore
A/S.
ZerAx®is a registered trademark of Novenco Building & Industry A/S.
AirBox™, NoVa™ and NovAx™ are trademarks of Novenco Building & Industry A/S.
The Novenco ZerAx processes of manufacture, technologies and designs are patented by
Novenco A/S or Novenco Building & Industry A/S.
Pending patents include India no. 821/CHENP/2014 and 825/CHENP/2014; PCT no. EP2012/
064908 and EP2012/064928.
Granted patents include Brazil no. BR-11-2012-008543-3; BR-11-2012-008545-0, BR-11-2012-
008607-3, BR-11-2014-002282-8 and BR-11-2014-002426-0; Canada no. 2.777.140, 2.777.141,
2.777.144, 2.832.131 and 2.843.132; China no. ZL2010800458842, ZL2010800460965,
ZL2010800464275 and ZL2012800387210; EU no. 2488759, 2488760, 2488761, 2739860 and
2739861; India no. 312464, 360298 and 367515; South Korea no. 10-1907239, 10-1933724, 10-
1980600, 10-2011515 and 10-2127529; US no. 8.967.983, 9.200.641, 9.273.696 B2, 9.683.577 and
9.926.943 B2.
Granted designs include Brazil no. BR-30-2012-003932-0; Canada no. 146333; China no. 1514732,
1517779, 1515003, 1555664 and 2312963; EU no. 001622945-0001 to 001622945-0009 and
001985391 - 0001; India no. 246293; South Korea no. 30-0735804; UK no. 001622945-0001 to
001622945-0009 and 001985391 - 0001; US no. D665895S, D683840S, D692119S, D704323S,
D712023S, D743018S, D755363S, D756500S, D821560S and D823452S.
Other trademarks in this document are the property of their respective owners.
This document is provided ’as is’. Novenco Building & Industry A/S reserves the right to
changes without further notice due to continuous product development.

Novenco ZerAx axial fan types AZL-AZN-AZW – Installation and maintenance 3 of 30
1. Application . . . . . . . . . . . . . . . . 4
1.1 Reading guide . . . . . . . . . . 4
2. Handling. . . . . . . . . . . . . . . . 4
2.1 Marking . . . . . . . . . . . . . . . 4
2.2 Weights. . . . . . . . . . . . . . . . 4
2.3 Design conditions . . . . . . . 5
2.4 Transport and lifting . . . . 5
3. Storage. . . . . . . . . . . . . . . . . 6
4. Installation. . . . . . . . . . . . . . 6
4.1 Before installation . . . . . . . 6
4.2 Set up fans . . . . . . . . . . . . . 7
4.3 Support frames . . . . . . . . . 8
4.4 Vibration dampers . . . . . . 9
4.5 Flexible connections . . . . . 9
4.6 Wire guards . . . . . . . . . . . . 9
4.7 Duct connection . . . . . . . . 9
4.8 Electrical connection. . . . 11
5. Start of operation . . . . . . . 12
5.1 Before start-up. . . . . . . . . 12
5.2 Motors with Y/-start . . 13
5.3 Start-up procedure . . . . . 13
5.4 Air volumes for free inlet
fans . . . . . . . . . . . . . . . . . . 13
6. Maintenance . . . . . . . . . . . 14
6.1 Before maintenance . . . . 15
6.2 Cleaning . . . . . . . . . . . . . . 15
6.3 Vibration levels . . . . . . . . 15
6.4 Fan casings. . . . . . . . . . . . 15
6.5 Rotors . . . . . . . . . . . . . . . . 15
6.6 Motors. . . . . . . . . . . . . . . . 16
6.7 Motor removal. . . . . . . . . 17
6.8 Mounting of motor . . . . . 18
6.9 Blade angles . . . . . . . . . . . 19
7. Troubleshooting . . . . . . . . 19
8. Inspection and test . . . . . . 19
9. Sound . . . . . . . . . . . . . . . . . 20
10. Safety . . . . . . . . . . . . . . . . . 20
11. Reference documentation 20
12. Disposal . . . . . . . . . . . . . . . 20
13. Quality management . . . . 21
14. Warranty . . . . . . . . . . . . . . 21
14.1Rotor weldings . . . . . . . . 21
15. Spare parts. . . . . . . . . . . . . 21
16. Classifications and certifica-
tions . . . . . . . . . . . . . . . . . . . . . 22
17. Product lifetime. . . . . . . . . 22
18. Declaration of conformity. 23
Appendices . . . . . . . . . . . . . . . . . . 25
Appendix - A.
Max. fan casing weights . . . . 25
Appendix - B.
Fan assembly . . . . . . . . . . . . . 26
Appendix - C.
How to mount puller. . . . . . . 27
Appendix - D.
Wiring – six-leads motor – no
frequency converter. . . . . . . . 28
Appendix - E.
Wiring – terminal box to fre-
quency converter . . . . . . . . . . 28
Appendix - F.
Wiring – three-leads motor –
with frequency converter . . . 28
Appendix - G.
Checklists . . . . . . . . . . . . . . . . 29
Contents

Novenco ZerAx axial fan types AZL-AZN-AZW – Installation and maintenance 4 of 30
1. Application
The high performance Novenco®ZerAx®axial flow fans types AZL-AZN-AZW are for
applications within land-based industries and marine sectors.All types arefor duct connection.
The AZL type has a free inlet and connects to duct on the outlet side.
1.1 Reading guide
Please read this complete guide, before beginning
installation or maintenance.
2. Handling
Avoid exposure of fans and motor parts to shocks, as these can result in imbalance and
deformations. Motor bearings and fan components are vulnerable parts.
2.1 Marking
The AZL-AZN-AZW fans have nameplates on the fans and motors.
2.2 Weights
The total weight depends on the fan size, casing thickness, motor size and accessories.
Refer to the technical fan specifications from Novenco AirBox program for further information
and weights of specific fan solutions.
Icons Descriptions
Risk of damage to equipment
Risk of injury or death
Installation tip
Table 1. Icons in guide


Fan nameplate information
•Manufacturer information
•Product type, e.g. AZN 1000/350
•Serial no.
•Fan speed
•Year of manufacture
•Weight
Motor nameplate information
•Manufacturer information
•Power consumption and efficiency
•Voltages
•RPMs
•Weight
•Terminal connections
•Lubrication and service info.

Novenco ZerAx axial fan types AZL-AZN-AZW – Installation and maintenance 5 of 30
2.3 Design conditions
The AZL-AZN-AZW fans are designed for operation at standard temperatures from -20 to
+50 °C. With reduced fan speed and increased blade clearance the temperature range can be
extended from -40 to +120 °C. Contact Novenco for further information.
2.4 Transport and lifting
The fans are delivered on pallets or bearers to
allow for forklift transport.
Transport and lifting must be done with care,
as the fans are vulnerable to vibrations and
shocks. These can result in imbalance and
deformations.
Refer to the weights in the shipping papers,
on the motor and fan casing nameplates and
in appendix “Appendix - A. Max. fan casing
weights”on page 25.
Any transport or lifting of the fans must
be in accordance to current directives,
regulations and guidelines for safety.
Pay attention to limitations and direction for
use of lifting gear.
Verify that the fans and accessories are
undamaged upon receipt. Also, spin the
rotors by hand to see they rotate freely in the
fan casings. Inform the carrier and Novenco
immediately of damages.


Further transport depends on the fan size and the fitted accessories.
Figure 1. Lift of fan with
one strap
Figure 2. Lift of fan with
two straps
Transport
•Fans mounted on support frames
Transport and store these on pallets.
Leave in the transport rods for fans with
vibration dampers.
•Fans without support frames
Transport fans resting on the inlet flanges
or cones. The rotors must point
downwards.
•Large fans or fans with large motors
Transport and store these on pallets.
Store very large fans on suitable bearers.
Eyebolts on motors are unsuited for
lifting the fans.
Lifting
•With straps – horizontal fans
Lift with a single strap around the fan
casing at the centre of gravity.
Avoid lifting fans in the flange holes.
Novenco recommends lift of fans with
straps.
•With straps – vertical fans
Lift with two straps around the fan
casing. Support the fan to control the
rotation especially for horizontal fan
installations.
•In flange holes – horizontal fans only
Lift in a minimum of three holes – two in
the outlet flange and one in the inlet. On
fans with inlet cones, remove the bolt in
the topmost position and use the hole as
the third point for lifting. Reinsert and
tighten the bolt once the fan is in place.
Deformation of the flanges must be
avoided.
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Novenco ZerAx axial fan types AZL-AZN-AZW – Installation and maintenance 6 of 30
3. Storage
Correct storage conditions are important for the
function and durability of the fans.
4. Installation
4.1 Before installation
Complete the below checklist to ensure a safe work environment and fan functionality. See also
the checklists in the appendices.
Before installation
•Unpack the fan with care.
•Check that the rotor rotates freely in the fan casing with equal blade tip distances to the
casing around the circumference.
•Outdoor installations: Make sure the installation location is sheltered. Fans, motors and
frequency converters must be protected from rain and water that drips.
•Ground the fan before installation to avoid static electricity. For example, by assembly on
non-conductive vibration dampers and foundations.
•Clear the fan installation location to ensure free and unimpeded airflows for the inlet and
outlet. The free area in front of the fan inlet must be at least 1x the fan diameter, D, or ½D
for optimal or reduced performance, respectively. Optimal airflow from all sides removes
risk of stall, gives best performance and keeps sound levels down.
•Secure the installation to at least IP20, i.e. protect people and surroundings against solid
Conditions Specifications Comments
Outdoor One month • Packaging must be intact
Indoor or sheltered Max. six months
• For unprotected fans with no or broken packaging
• Ventilated location
• No condensation
Prolonged Max. two years
• Indoor
• Remove packaging
• Ventilated location
• No condensation
• Turn rotor 20 times every six months
• Add additional anti-corrosive coating on motor shaft
• Change motor ball bearings after two years of storage
Vibrations No • Location must be vibration free
Temperatures -20 to 50 °C
• Constant temperature, preferably 20 °C
• Ventilated
• No condensation
Humidity Below 70%
• Avoid condensation
• Exceedance requires airtight packaging of complete fan and use of
a moisture absorbent agent such as silica gel
Table 2. Storage recommendations
Damages due to incorrect storage
void the warranty.
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Novenco ZerAx axial fan types AZL-AZN-AZW – Installation and maintenance 7 of 30
objects up to 12 mm.
Also, install wire guards on fans where there is direct access to the rotor. Wire guards from
Novenco can be installed as close as 120 mm before and after the rotor.
See section “4.7 Duct connection”for minimum distances for undisturbed airflow.
The vibration level of the installation depends on how the fans are installed, the
operational conditions and the natural frequency of the foundation and supports.
Follow the below guidelines to avoid resonance.
•Soft suspension: Fan is fixated through springs or dampers. The natural frequency
[Hz] of the system should be at least 20% below fan speed.
Soft suspensions are available from Novenco.
•Stiff suspension: Fan is fastened to a duct or a hard surface. The natural frequency
of this system should be at least 20% above fan speed.
•Elastic structure: Fan is fastened to an elastic structure. The natural system
frequency should be at least 20% higher or lower than fan speed.
The owner is responsible for compliance with the above requirements. Non-compliance
affects the product warranty.
4.2 Set up fans
Prepare fans for installation
1. Fit the support options needed for mounting the fan. This may include the following.
•Special carriers
•Support frame (recommended)
•Mounting plate
•Vibration dampers (recommended)
Proper support ensures safety and installation stability. See sections “4.3 Support frames”
and “4.4 Vibration dampers”.
The fan support must be strong enough to support the fan weight and any fittedaccessories.
See “Appendix - A. Max. fan casing weights”on page 25 and the Total weight of installation
in the technical fan specifications from AirBox.
2. Optional: Install flexible connections on the fan flanges.
See section “4.5 Flexible connections”on page 9.
3. Optional: Install wire guards on one or both sides of the fan casing.
See section “4.6 Wire guards”on page 9.
Connect fans
1. Check that the fan motor drain holes point
downward and are in the lowest possible location.
Adjust the fan position, if necessary.
2. Unplug the fan motor drain holes.
3. Place and orient the fan in accordance with the
airflow. Refer to the arrows on the fan casing.
•Duct fans: These can be installed horizontally
or vertically as part of duct works or connected
to duct openings as supply or exhaust fans.
The installation space must at least meet the
reduced requirements and preferably those for
optimum installation space. See section “4.7 Duct connection”on page 9.

The motor drain holes must
point downwards at the lowest
point as the installation
environment and operation
conditions may cause condensation
in the fan motors. Fan motors
mounted at angles typically have the
drain holes in the back covers.
Contact Novenco if the drain holes
are missing.
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Novenco ZerAx axial fan types AZL-AZN-AZW – Installation and maintenance 8 of 30
•Fans on support frames and AHU
incorporation: Fans mounted on support
frames can be connected to wall openings, duct
works or incorporated in AHUs.
Remove the transport rods in the support
frames for fans delivered on support frames
and with vibration dampers. The handles are
marked with a strong colour.
See section “4.7 Duct connection”on page 9 for
installation space requirements.
4. Check that the fan rotors rotate freely once the fans
are in position.
5. Connect fan to duct or similar mounting point in
the fan flange.
6. Connect fan electrically.
See section “4.8 Electrical connection”on page 11.
4.3 Support frames
Support frames are optional extras and recommended
for most fan installations.
All ZerAx fan types can be fitted with support frames
for horizontal installation. In figure 4, support frame
types 1 and 2 are for horizontal installation of the AZL. The type 2 can furthermore be mounted
on rails transversally to the airflow for easy incorporation in AHUs.
Support frames type 3 are for horizontal installation of the AZN and AZW.
For vertical fan installations, the type 4 is available for the AZL and AZN. The AZW cannot be
installed vertically.
Figure 3. Transport rods in AZL support
frame
Support frames must be
groundedto preventelectrical
shocks.
Figure 4. Novenco ZerAx support frames
01
02
Type 1 - Horizontal frame for AZL
Type 2 - Compact horizontal frame for AZL
and suited for incorporation in AHUs
03
M10x20
02
01
Type 3 - Horizontal frame for AZN and AZW
01
02
Type 4 - Vertical frame for AZL and AZN with
(left) and without vibration dampers
01
02
1. Frame plates
2. Vibration dampers (optional)
3. Stiffeners

Novenco ZerAx axial fan types AZL-AZN-AZW – Installation and maintenance 9 of 30
4.4 Vibration dampers
Secure vibration dampers to the support frames by
means of bolts. Mount base plates between the rubber
elements and the foundation.
The vibration dampers help ensure the natural
frequency of the system is below 10 Hz and that the
damping is at least 80%.
Ensure an even load of the vibration dampers by
placement of the fan the distance X from the centre of the
front damper element to fan front flange. See figure 5.
The distance is in the technical fan specifications from the
AirBox program.
The load of the dampers depends on air pressure.
4.5 Flexible connections
To prevent spread of vibrations to the surroundings,
it is recommended, in addition to vibration dampers,
also to install flexible connections in the ducts before
and after the fans. These accessories are available as
optional extras from Novenco.
4.6 Wire guards
Fans must always be installed so that parts
that rotate cannot be touched or fly off in case
of material failure. It is therefore
recommended to fit wire guards on the inlet
and outlet sides. If ducts are connected, these
can alternatively be provided with wire
guards.
Novenco offers wire guards for in-pipe
installation on outlets. Drill holes in the pipe
and fixate with the bolts and nuts included in
the kit.
4.7 Duct connection
Install the fans with optimal conditions in mind to
ensure smooth and undisturbed airflows. The space
before and after the fans should preferably meet the
optimal requirements in the below figure.
Allow for free areas to facilitate assembly and
disassembly as well as maintenance.
X
Figure 5. AZN-AZW on support frame
Uneven damper loading
strains and reduces damper
functionality.

The natural frequency of the
support must lie at least 20%
from the fan speed.

20 mmEyebolt
Nut
Figure 6. In-pipe installation of wire guard
The fans cannot be used as
structural elements, e.g. for
duct or building support.
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Novenco ZerAx axial fan types AZL-AZN-AZW – Installation and maintenance 10 of 30
Flexible connections can be placed as close as ½D before the fan inlet.
Figure 7. Installation spaces in ducts – optimal (left) and reduced
D>D>
½Dr>
½D>D>
Built into duct
Free inlet D = Fan diameter
3 x D>3 x D>
½Dr>
D>D>
D = Fan diameter
Built into duct
Free inlet
Figure 8. Installation in duct
Figure 9. Installation in duct
Fan size,
ØD, [mm]
RPM 1 2
1. Fan speeds depend on the installation space.
2. Fans with Ø160 hubs can run at maximum RPMs
irrespective of the installation conditions.
Maximum Optimal Reduced
Hub diameters
160
250 4919 — —
280 4747 — —
315 4570 — —
355 4408 — —
400 4269 — —
450 4145 — —
500 4086 — —
Hub diameters
350
500 3660 3660 3483
560 3460 3460 3286
630 3238 3238 3059
710 3000 3000 2804
800 2751 2751 2523
900 2498 2498 2217
1000 2270 2270 1918
1120 2029 1900 1568
1250 1809 1500 1201
Hub diameters
560
1000 2034 2034 1904
1120 1893 1893 1727
1250 1751 1751 1552
1400 1599 1599 1371
1600 1419 1419 1166
1800 1262 1262 1002
2000 1130 1130 878
Table 3. Max. allowable speed at 20 °C
AZN-AZW fans are for circular duct
connections with flanges on both inlet and
outlet sides. The AZL has a flange on the outlet
side only.
Flanges on AZL-AZN fans are as standard
according to Eurovent 1/2. Fan type AZW has
flanges of type DIN 24154 row 4 as standard.
Systems with high vibration levels or more
exacting performance requirements must be
provided with expansion joints between fan
and duct.

Novenco ZerAx axial fan types AZL-AZN-AZW – Installation and maintenance 11 of 30
4.8 Electrical connection
The installation and connection to the supply network must be done by authorised
personnel and according to current legislation, e.g. the EU standard for electromagnetic
compatibility (EMC).
Connection of the fans to the supply network depends on the drive type, i.e. if frequency
converters are to control the fan motors.
Connection of drive types
•Fixed speed (Direct On Line)
- Connect the supply voltage directly in the
terminal box.
•Frequency converter (AC and PM motors)
- Connect the supply voltage to the frequency
converter and the converter to the terminal box.
The terminal box is on the outside of the fan casing.
Connection diagrams are inside the box lid.
The cable run must be in accordance with current
regulations, e.g. the EU standard for electromagnetic compatibility (EMC).
Frequency converters must be installed in accordance to the manufacturer’s installation
documentation. Refer also to the Novenco document “Configuration of frequency converters
for Novenco fans”.
Shield and connect the fans electrically to ground to eliminate interference and protect the
motor bearings and windings.
Refer to the motor documentation for methods to avoid impairment of the supply voltage
quality, among them distances between supply and signal cables. Methods may involve
installation of rectifiers, filters etc.
ZerAx fans with
permanent magnet (PM)
motors require connection
through frequency converters.
Direct connection of the supply
voltage in the terminal boxes on
PM motors ruins the motors and
voids the warranty.

Connection references
•Connection diagram in terminal box lid
on fan
•Motor nameplate
•Order specification
•Appendices D, E and F on wiring on
page 28
Verify that the rotational direction of
the rotor complies with the arrow on
the outside of the fan casing. Flick the
fan power briefly On, then Off. If the
direction is wrong, disconnect the
main power supply and check the
connections.
Only fans with steel inner hubs may be run in
reverse and this for short periods at speeds up
to the max. allowable of normal direction. The
airflow is reduced to approx. 50% of normal for the
same system resistance. The pressure is reduced to
25%.
Reversible operation increases the risk of stall and
shortens fan life.
The rotor must be completely stationary, before
restart of the fan for directional change of rotation. It
is recommended to install a time delay for this
purpose.
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Novenco ZerAx axial fan types AZL-AZN-AZW – Installation and maintenance 12 of 30
5. Start of operation
Fans fitted with frequency converters must have the control unit set up, before start of
operation. Refer to the Novenco document “Configuration of frequency converters for
Novenco fans”.
Perform the below steps every time the fans have been stopped.
5.1 Before start-up
Check the fans and installation location in accordance to the below checklist and correct and
improve as necessary. See also the checklists in the appendices.
Checklist

•Safe operation
The blade clearance must be minimum
0.1x motor shaft diameter (min. 2 mm,
max. 13 mm) all around the rotor
circumference.
The axial distance between the rotor hub
and stator must be min. 3.5 mm.
Wire guards should be mounted on the
inlet and outlet sides.
•Transport rods
Fans on support frames and with
vibration dampers have transport rods in
the support frames, which must be
removed before start of operation. The
handles are marked with a strong colour.
•Clean ducts
The fans and duct connections must be
clean and free from tools and objects that
can affect the airflow.
•Electrical connections
The electrical connections must be
correct and in accordance to the
prescribed requirements. Switch the fan
power briefly On, then Off, to check the
rotational direction of the rotor.

Novenco ZerAx axial fan types AZL-AZN-AZW – Installation and maintenance 13 of 30
5.2 Motors with Y/start
Set the relay for start of the fans to the
Start-up time from the technical
specifications from the AirBox
program. Alternatively, calculate the
value with the formula.
The motor torque can vary within the
below limits and affect the start-up
time.
5.3 Start-up procedure
Refer to the motor manual and the technical specifications from theAirBox program for specific
information and procedures.
Start-up procedure
1. Start the fan.
2. Check that no abnormal noises are present.
3. Check that the vibration levels are
acceptable.
See section “6.3 Vibration levels”.
4. Check that the fan operates normally after
30 minutes of operation.
5.4 Air volumes for free inlet fans
For fans with measuring pipes and free inlets, the air volume can be calculated as shown below.
The measuring pipes are optional accessories and fitted close to the fan inlet.
The below formula gives the air volume in m3/s. Multiply by 3,600 to convert to m3/h, or by
Ms: -15% to +25% of
catalogue value
Mk: -10% to 0% of
catalogue value
Calculation of start-up time
ts=
ts: Start-up time [s]
P: Rated output of motor [kW]
Pv: Required power of fan [kW]
n: Fan speed [RPM]
:Ratio between the start and the nominal
motor torque
:Ratio between maximum and nominal
motor torque
Iv: Polar moment of inertia for fan [kgm2]
Im: Polar moment of inertia for motor [kgm2]
0.24 n2ImIv
+ 
104PMs
M
-------
Mk
M
--------
Pv
P
------–+
 
 

-----------------------------------------------------------------
Ms
M
-------
Mk
M
--------
The fans aredesigned for continuous
operation. The below kinds of
operation may cause fatigue breaks
in the rotors and endanger people.
•Operation in stall area, i.e. with
counter pressure that pulsates -
called pump mode
•Operation with uninterrupted
and repeated starts and stops
•Uneven flow velocity through
the fans
Ask Novenco if in doubt.

Novenco ZerAx axial fan types AZL-AZN-AZW – Installation and maintenance 14 of 30
2188.88 to convert from m3/s to CFM.
For the fan types AZN and AZW with wire guards, the constant in table 3 must be reduced by
up to 10%. For these fan types without wire guards, the constant is used directly.
For the AZL with wire guards, the constant must be reduced by up to 20%. For this fan type
without wire guards, the constant must be reduced by 10%.
Free inlet cones are integrated on the AZL and is an accessory for the AZN and AZW.
The suction must be directly from the suction chamber.
Fans with low blade angles can make noise at high pressures, which affects the measurement.
Operation close to the stalling area produces poor results also.
6. Maintenance
In the following, please also see “Appendix - G. Checklists”on page 29.
Figure 10.Measurement of pressure
difference
q=
q:Air volume [m3/s]
k:A constant, see table 3.
dps :Difference between paway and pfan
[Pa]
pfan :Static pressure at fan inlet [Pa]
paway :Static pressure away from fan [Pa]
paway
pfan
k dps
Fan sizes Constant, k Fan sizes Constant, k
250/160 0.0510 900/350 0.7204
280/160 0.0694 1000/350 0.9001
315/160 0.0917 1120/350 1.2019
355/160 0.1183 1250/350 1.5636
400/160 0.1502 1000/560 0.871
450/160 0.1894 1120/560 1.129
500/160 0.2343 1250/560 1.441
500/350 0.1921 1400/560 1.844
560/350 0.2537 1600/560 2.453
630/350 0.3324 1800/560 3.142
710/350 0.4329 2000/560 3.913
800/350 0.5603
Table 3. Constants for calculation of air
volumes for ZerAx fans
Test and
inspection 1
1.The site operator may have set other test intervals. Smoke control fans and other fans, which run infrequently
or in case of emergencies, must be run tested every week, for example during normal operation.
Service and
lubrication 2
2.The motor manufacturer’s recommendations may call for shorter lubrication intervals. See section “6.6 Motors”
on page 16. Please note that fans with permanent magnet motors are lubricated for life.
Cleaning 3
3.Intervals for cleaning depend on the operating conditions and environment. See section “6.2 Cleaning” on page
15.
Bearings
Fan types Bearing types
Standard temperature Sealed for life 6 months
6 months 3 months 3 months
Lubricated
Smoke — Weekly +
6 months
ATEX and EX —
Table 4. Maintenance intervals

Novenco ZerAx axial fan types AZL-AZN-AZW – Installation and maintenance 15 of 30
Repair and maintenance of Novenco fans must be carried out by authorised personnel
and in accordance with Novenco instructions. Keep records signed by the competent
personnel for all services, tests and changes performed.
6.1 Before maintenance
Switch off the power and disconnect the motor cable in the terminal box, before
beginning work on the rotor and motor.
For fans with PM motors, make sure the motor axles cannot rotate during service, e.g.
by blocking the fan rotors. PM motors can generate high voltages when the motor axles rotate,
even though the power is disconnected.
6.2 Cleaning
Clean the fans at least quarterly. The intervals may have to be adjusted, dependent on the
operation and operational conditions. Corrosive and dust filled atmospheres typically shorten
the intervals. Please note that deposits of dust can be ignited by high surface temperatures and
constitute a safety risk.
6.3 Vibration levels
After installation and also in connection with regular
inspection and cleaning, the vibration levels must be
measured and be less than or equal to max. 6.3 mm/s.
Measure the levels at operational fan speed, radially at two
points with a 90° offset and at the free shaft end of the motor.
Fans that exceed the limits usually require cleaning or
balancing of the rotors. Alternatively, the causes must be
investigated and removed. Refer to ISO 14694.
For variable speed fans the vibration level limits are likely
to be exceeded at certain speeds. Continuous operation at
these speeds must be avoided.
6.4 Fan casings
The fan casings require no other maintenance than ordinary cleaning.
Check painted casings regularly and keep them in good condition.
6.5 Rotors
The rotors are carefully balanced and the rotor blades are set at precise angles in the production.
The rotors are thereby optimised for vibration free operation at the desired operation point with
regard to pressure, airflow and fan speed.
Fan vibration levels
depend on installation
type and fan speed.
Vibrationshavesignificanteffect
on fan life and efficiency.

Shut down fans with
vibration levels that
exceed 12.5 mm/s RMS.
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Novenco ZerAx axial fan types AZL-AZN-AZW – Installation and maintenance 16 of 30
Vibrations that occur in operation may be due to accumulation of dust and dirt on the hubs and
blades. If vibrations persist after cleaning, expert assistance should be called for immediately.
Continued operation with vibrations shorten the life of the fan and motor bearings.
6.6 Motors
Refer to the motor manufacturer’s documentation and the nameplates for how to service the
motors.
Motor maintenance
•Lubricate bearings
Refer to the motor manual for service information such as lubrication intervals, grease
amounts, when to replace bearings etc. Observe differences between motor Drive End (DE)
and Non-Drive End (NDE).
-Permanent magnet motors are lifetime lubricated. Bearings may, however, need
replacement.
-AC motors up to size 132 have lifetime-lubricated
bearings. Motor sizes 160 to 280 require lubrication
according to the manufacturer’s instructions.
Fans with motor sizes 225 to 280 have nipples on the
outer fan casings. For fans with motor sizes 160 to 200,
nipples on the outer fan casings are optional.
Refer to the motor nameplates for recommended
grease type, amount and interval.
•Inspect the motor for wear signs and
damaged parts.
•Clean the motor casing, motor cooling
fan and motor shell.
•Drain the motor of condensed water.
•Check supply cables and electrical
connections for impairments.
•Check terminal box seals and cable
glands.
Use a manual grease
gun for lubrication.
Excess grease causes
bearings to overheat and
results in failure.
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Novenco ZerAx axial fan types AZL-AZN-AZW – Installation and maintenance 17 of 30
6.7 Motor removal
Switch off the power and disconnect the motor cable in the terminal box, before
beginning work on the rotor and motor.
For fans with PM motors, make sure the motor axles cannot rotate during service, e.g.
by blocking the fan rotors. PM motors can generate high voltages when the motor axles rotate,
even though the power is disconnected.
The below procedure is with reference to figures 12 and 13 beginning on page 26.
Motor removal
1. Dismount any ducts on the inlet and outlet sides.
2. Remove the screws (figure 12, comp. 1) that hold the hub
cap and remove the cap (figure 12, comp. 2).
3. Remove the rotor centre bolt and washers (figure 12,
comp. 3).
4. Fans with hub clips: Remove the hub clip, screws and
washers (figure 12, comp. 4).
5. Dismount the rotor with a puller fastened in the threaded holes of the hub boss (figure 12,
comp. 5). See also figure 13. “Mounting of puller in Ø350 hubs with hub clips” on page 27
6. Disconnect the motor cable from the motor.
7. Support the motor. See the technical fan specifications from the AirBox program.
Motor
size Poles
Lubrication
intervals [hours]
50 Hz 60 Hz
160
2 22000 20000
4
25000 250006
8
180
2 17000 14000
4
25000 250006
8
200
2 15000 12000
4
25000 250006
8
225
250
280
2 5000 4000
4 14000 12000
6 20000 17000
8 24000 20000
2 4000 4000
4 13000 10000
6 18000 16000
8 20000 20000
Table 5. Grease amounts and intervals for WEG
W22 TEFC motors – ball bearings
Motor
size Poles
Lubrication
intervals [hours]
50 Hz 60 Hz
160
2 16000 12000
4
25000 250006
8
180
2 11000 8000
4
25000 250006
8
200
2 9000 6000
4
25000
21000
625000
8
225
250
280
4 11000 9000
6 16000 13000
8 20000 19000
4 9000 7000
6 14000 12000
8 19000 17000
Table 6. Grease amounts and intervals for WEG
W22 TEFC motors – roller bearings
Avoid exposure of fans
and motor parts to
shocks, as these can
result in imbalance and
deformations. Motor bearings
and fan components are
vulnerable parts.
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Novenco ZerAx axial fan types AZL-AZN-AZW – Installation and maintenance 18 of 30
8. Detach the motor from the motor shell by removing the nuts and bolts (figure 12, comp. 7a
and 7b) for hub sizes Ø350 and Ø560, or bolts and washers (figure 12, comp. 7b and 7c) for
hub sizes Ø160.
Notice: Access nuts holding motors mounted in rear motor shells through the front motor
shells.
9. Remove the motor (figure 12, comp. 8).
6.8 Mounting of motor
The component numbers in the below procedure refer
to figure 12 on page 26.
Mounting of motor
1. Remount the motor (comp. 8) and make sure the
motor shaft is centred in the fan casing.
A centring tool is available as an accessory from
Novenco.
2. Fans with Ø350 hubs and motor sizes 160 or 180:
These motors are mounted with pins. The pins
must be replaced with new ones when re-
mounting the motors.
3. Insert and tighten the nuts and bolts (comp. 7a and 7b) to the prescribed torques for hub
sizes Ø350 and Ø560, or bolts and washers (comp. 7b and 7c) for hub sizes Ø160. See table 9
on page 26.
Notice: Access nuts holding motors mounted in rear motor shells through the front motor
shells.
4. Mount the rotor (comp. 6) on the motor shaft with a tool fastened in the threaded hole of
the motor shaft. The rotor hub must rest against the motor shaft collar.
5. Use a feeler gauge to check that the blade tip
clearance between the rotor blade tips and
fan casing is the same throughout the
circumference.
6. Adjust the motor position. See step 5.
7. Mount the centre washers and bolt (comp.
3).
8. Fans with hub clips: Mount the hub clip,
screws and washers (comp. 4).
9. Mount the hub cap (comp. 2) and screws
(comp. 1).
10. Connect the motor cable to the motor and the
power cables in the terminal box.
11. Reconnect any ducts.
Follow the procedure in section “5. Start of operation”to start the fan.
Replace lock washers and nuts
during assembly.

Consult Novenco if the
replacement motor weight
exceeds the original
specifications. Refer to the technical
specifications from the AirBox
program.
Hub,
[mm]
Rotor,
ØD [mm]
Min.
[mm]
Hub,
[mm]
Rotor,
ØD [mm]
Min.
[mm]
Ø160
250 0.5
Ø560
1000 0.8
280 0.5 1120 0.9
315 0.5 1250 1.0
355 0.5 1400 1.1
400 0.5 1600 1.3
450 0.5 1800 1.4
500 0.5 2000 1.6
Ø350
500 0.5
Ø350
900 0.9
560 0.6 1000 1.0
630 0.6 1120 1.1
710 0.7 1250 1.3
800 0.8
Table 7. Blade tip clearances at standard
temperatures

Novenco ZerAx axial fan types AZL-AZN-AZW – Installation and maintenance 19 of 30
6.9 Blade angles
The fan rotor blade angles are the result of careful calculations to achieve a specific and
sometimes delicate point of operation. The mount on the hub and balancing are therefore
closely related to the angles and cannot be changed. Please contact Novenco for further
information.
7. Troubleshooting
Check for the below faults in case of breakdowns or lack in
performance. Call for service, if problems persist.
8. Inspection and test
It is recommended to test and inspect the fans at regular intervals with regard to operability
and operation conditions.
Inspect the fans twice a year to ensure satisfactory function and long product life. Fans with
inspection hatches allow for inspection through these.
Extent of inspection
Novenco recommends keeping a log of all values and observations regarding the fans.
Lack in performance
•Blocked
- Inlets
- Outlets
- Dampers
•Supply air reduced
•Motors defective
•Motors disconnected
•Wrong fan rotation direction
Noises and vibrations
•Motor bearings defective
•Rotors out of balance
•Rotors damaged or worn
•Bolts or components loose
•Wrong rotor blade pitch angles
Fans that operate in the
stall area are more likely
break down.

•Measure power consumption
•Verify torques of fixation bolts
•Cleaning
- inside with pressurised air
- outside with a lint-free cloth witha mild
soapy water solution
•Visual inspection
- Rotors
- Fan casings
- Electrical connections

Novenco ZerAx axial fan types AZL-AZN-AZW – Installation and maintenance 20 of 30
9. Sound
The sound emissions depend on the installation and operation conditions, hence no general
data can be given.
Refer to the technical specifications from the AirBox calculation program for specific emissions
and to the product catalogue for more general data.
10. Safety
The installation must be in accordance to Novenco’s, the current and the local safety
regulations. At a minimum these include EN 13850.
It is recommended to review and revise safety procedures regularly.
11. Reference documentation
Please refer to the below documents for further information about the fans.
12. Disposal
Dispose of fans suitable for scrapping in environmentally safe ways and in accordance to
current regulations.
The fans and especially the electric motors contain recyclable materials. Make sure worn-out
motors and fan parts are disassembled and recycled for the benefit of the environment.
•Test if safety procedures and the
installation work correctly.
•Check for changes in safety regulations
and revise the installation accordingly.
•Consider additional measures to
improve the safety of the installation.
Safety check
•Catalogue
ZerAx axial flow fans standard, ATEX
and EX
•Novenco configuration user guide
Frequency converter Danfoss FC101
•Technical specifications