KALE FANS BOREAS Series User manual

KaLe Environmental Technology(Shanghai)Corp.
KaLe Environmental Technology(Shanghai)Corp.
Quick installation guide
BOREAS
Tel: [phone] Fax: [phone]
Web:www.kalefans.net Email:[email protected]
Origin: China
KL-YS-SMSEN-0307

INSTALLATION GUIDE
KALE FANS
www.kalefans.net
2019
Contents
-1-
Preface…………………………………………………………………………………………………2
1. Production series introduction……………………………………………………..3
1.1 Product specification table…………………………………………………3
2. Product drawing………………………………………………………………………4
2.1 Standard components introduction……………………………………5
2.2 Packing list…………………………………………………………………………6
2.3 Universal installation tools…………………………………………………8
3. Installation conditions and types………………………………………………….8
3.1 Roof installation requirement……………………………………………8
3.2 I-beam steel structure………………………………………………………9
3.3 Concrete structure…………………………………………………………….9
3.4 Angle-concrete bent structure……………………………………………9
4. Fan installation procedures………………………………………………………….10
5. Specification of parameters for control system.…………………………….13
6. Operating instructions………………………………………….…………………14
7. Safety instructions……………………………….……………….……………………..14
8. Troubleshooting……………………………………….…………….……….…………..15
8.1 Explanation of error codes…………...……………….……………….………..15
9. Customer service………………………………………….………………….……..16
10. Fan working condition…………………………………..……………….………17
11. Quality assurance…………………………………….………………….……………17
12. Warranty and maintenance ...……………………….………………………….18

Preface
Thanks and congratulate for your purchasing of the KL-HVLS series big energy-saving fan! Now you have acquired the most
effective shortcuts to pass a cool summer and warm winter. No matter in the industrial or utility applications, it possesses relatively
high cost performance. More importantly, our products have passed the strict quality inspection and a variety of safety tests, and
you can rest assured the operation.
If you have any questions and comments to our products, you can contract us through [phone], or access to our website
www.kalefans.net. Before the usage, please make sure that you have read the operation instruction manual.
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INSTALLATION GUIDE
BOREAS

INSTALLATION GUIDE
KALE FANS
www.kalefans.net
2019
BOREAS series
BOREAS series Big Energy-Saving fan is a super fan with a diameter of 7.3m! Kale Airfoil Blades, which are streamlined,
are developed with the advanced technologies and the principle of aerodynamics. With a power of 1.5KW or less, the
blade is able to drive a mass of air and makes the natural wind system with ultra-large area, which leads to the double
function of ventilation and temperature reduction. Compared to the traditional HVAC conditioner and small high-speed
air blower, the fan is superior in application, and that makes it immaculate for the large space to ventilate and reduce
temperature. BOREAS Series fan is a primary product for KALEFANS and its coverage can be up to 1600 sq metres. The
fans are mainly applied in large space such as the plant, logistics & warehouse, supermarket and farm, etc.
1.1 Product specification table
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1. Production series introduction
技术规格 Technical Specifications 20ft（6.1m）24ft（7.3m）
型号Model D4BAA61 D4BAA73
满载风量 Air disp.@Max speed
12000m³/min 13050m³/min
最大转速 Maximum speed 70RPM 60RPM
风扇主体重量 Fan weight 97kg 110kg
电机功率 Moto size 1.5Kw 1.5Kw
满载电流 Full load amps 3.5Amps/380V 5.7Amps/220V 3.5Amps/380V 5.7Amps/220V
注：
1、重量计算：产品重量不包含控制箱，
顶部连接构件等。
2、尺寸：以上所列产品尺寸为标准品，
其他规格尺寸可定制。
3、噪音：声级计距离电机1m,电磁噪音
40dB(A)以下。
4、包装：标准木箱包装。
5、输入电源：三相380V/220V,单相
220V可选。
Note:
1, Weight: the weight does'nt contain control box, top connection parts
etc.
2, Size: the above-mentioned product size is standard, other size can be
customized.
3, Noise: sound level measured a distance of 1 m from the motor,
electromagnetic noise is less than 40 db(A).
4, Packing: Export standard crates.
5, Input power: 380 VAC, 3P, 50/60 Hz.220 VAC, 3P, 50/60 Hz.220 VAC, 1P,
50/60 Hz.

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2. Product drawing
INSTALLATION GUIDE
BOREAS
1. Steel structure 6. Winglet of fan blade
2. Safety ring 7. Fan blades
3. Steel structure fastening 8. Turnbuckle and clamps
4. Extension tube 9. Traction steel wire
5. Main body 10. I-type safety adapting pieces
1
2
3
4
5
6
7
8
9
10

INSTALLATION GUIDE
KALE FANS
www.kalefans.net
2019
motor housing
power system
main body frame
grommet for
steel wire
Safety collar
fan hub
5 Main body structure3 Steel structure fastening
Control system structure
fastener
pressure plate
shim
steel structure
top plate
adapting piece
for extension tube
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2.1 Standard components introduction
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FROM KALE FANS
HOUR SERVICE HOTLINE
Before operating the unit,please read the product
description carefully,and clear obstacles from the
regional operation.Ensure there is enough distance
for the fans running.
WARNING：Make sure to cut off the power before
do any maintenance of electrical and fans,by the
professional operation,to avoid being hit by power！
To prolong the service life and ensure long-term
stable operation of products, please do the
maintenance according to the << Product
maintenance manual>>.
display window
lock
control switch
speed switch

KALEFANS
2.2 Packing list
Packing specification
CASE NO
(L*W*Hmm)
DIMENSION
（m
3
）（kg）
1
945*825*510 0.4 134 main body
carton
No. DESCRIPTION No. DESCRIPTION
1Main Body 10 Metal Joint
2Control Box 11 Turnbuckle
3Top Plate 12 Fastener
4Shim 13 Steel Wire Clamp
5Clamp Plate 14 Metal Joint
6LOGO 15 Hose Clamp
7I-type adapting pieces 16 Expansion Pipe
8Steel Wire
9Power Cable
Packing details
High Strength
Drywall Screw
17
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INSTALLATION GUIDE
BOREAS
Remark
Gross
weight
Volume
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FROM KALE FANS
HOURSERVICE HOTLINE
Beforeoperating the unit,please read the product
descriptioncarefully,and clear obstacles from the
regionaloperation.Ensure there is enough distance
forthe fans running.
WARNING：Makesure to cut off the power before
doany maintenance of electrical and fans,by the
professionaloperation,to avoid being hit by power！
Toprolong the service life and ensure long-term
stableoperation of products, please do the
maintenanceaccording to the << Product
maintenancemanual>>.

INSTALLATION GUIDE
KALE FANS
www.kalefans.net
2019
KALEFANS
No. DESCRIPTION
1Fan Blade
2Extension Tube
3Cardan Joint
4Fastener
Packing details
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Packing specification
CASE NO
(L*W*Hmm)
DIMENSION
（m
3
）（kg）
23750*415*390 0.61 76 fan blade
carton
Remark
Gross
weight
Volume

3.1 Roof installation requirement
2.3 Universal installation tools
3. Installation conditions and types
spanner Socket wrench screw driver multimeter
distance meter screw gluewire-cuttergradienter
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INSTALLATION GUIDE
BOREAS
800 MM
Minimum distance is 1.1M
Minimum distance is 0.2M
Minimum distance is 3.5M
distance is 0-6M
7.3M(24FT)

INSTALLATION GUIDE
KALE FANS
www.kalefans.net
2019
3.3 Concrete structure
3.4 Angle-concrete bent structure
3.2 I-beam steel structure
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4. Fan installation procedures
1Preparation
2confirmation
3Inspection
4Top plate
5Extension rod
6Safety rope
7power cable
Notice: When unloading product should put down gently when unloading,
product’s position should not affect the field production and channel.
Notice: Carefully confirm the following information 1, Installation point 2, installation
height 3, whether there are obstacles (such as crane, light, Cable, fire protection,
cameras) 4, control cabinet position 5, the input power and the power cord layout, 6,
power line layout, 7, traction steel wire position.
Notice: Check the security measures (such as seat belts, helmets, etc.), climbing
equipment, tools, products and accessories.
Notice: the extension tube is 90 degrees measured with a gradienter.
Notice: keep the surface of the cable good and 20cm out of the tube is ok after
threading.
Notice: Both sides of the top plate is same and isometric, top plate must be vertical to
the H-beam and the shim need to be close to H-beam, clamping pieces are fully
combined with the beam. Other installation types should reach the same standard.
Extension rod
Pressure plate
fastener
Steel structure
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INSTALLATION GUIDE
BOREAS
Notice: the safety rope(steel wire) should entwine around the beam.

INSTALLATION GUIDE
KALE FANS
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8Main body
9wiring
10 steel wire
11 power cable
12 Fan blades
13 Logo
Notice: keep the upper and under plane
horizontal, then tighten up the relevant bolts.
Notice: Don't cut the copper wire when stripping off, first connect ground wire
(yellow-green one or yellow one if no yellow-green), connect one-to-one according
to the color and then wrapped with insulating tape.
Notice: Four steel wires should be isometric, symmetrical, ensure all points bear stress
evenly, the steel wire clamps must be tightened up and glued, same with the
turnbuckles.
Notice: Wiring should be tight, firm and nice-looking.
Notice: Keeping the blade surface good and install diagonally, two people work
together will be the best so that can ensure the tightening effect.
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14 I-type pieces
15
control system
16 wiring
17 Debugging
18
Commissioning
19 acceptance
20 Cleaning
21 Finish
Notice: the oval hole is under the round hole.
Notice: the height from floor to the bottom of the control box should be around 1.2
meter.
Notice: distinguish the input and output, also make sure the ground wire is in place.
Notice: all the parameters had well set before delivery in factory.
Notice: Running for 15 minutes, check it whether there is a abnormal sound and steel
wire jitter as well as the current within the rated range.
Notice: provide relevant specification, certificate of approval to customers and inform
the precautions , the customer sign the acceptance sheet at last.
Notice: clean the area after finishing the installation work, customer’s equipments
and subjects should be put in order, bring back all the installation tools and
accessories.
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INSTALLATION GUIDE
BOREAS

INSTALLATION GUIDE
KALE FANS
www.kalefans.net
2019
5. Control panel and display
-13-

www.kalefans.net
FROM KALE FANS
HOUR SERVICE HOTLINE
Before operating the unit,please read the product
description carefully,and clear obstacles from the
regional operation.Ensure there is enough distance
for the fans running.
WARNING：Make sure to cut off the power before
do any maintenance of electrical and fans,by the
professional operation,to avoid being hit by power！
To prolong the service life and ensure long-term
stable operation of products, please do the
maintenance according to the << Product
maintenance manual>>.
6. Operating instructions
Three gears control switch
Three gears control switch is the electrical device that controls OFF, RUN and
Reset, and is belongs to weak current control switch. It directly controls the
frequency converter.
Run: Fans are running forward, winds blowing downward.Off: Fans stop
running.Reset.
7. Safety instructions
Prohibitions
In the installation, adjustment and the cleaning processes please don’t bend the fan blades, or it will damage the equipment
or affect using effects.
Please make sure the fan's input voltage and supply voltage are the same before cut-in the power.
Please don’t proceed examine and repair works while power on so as to prevent electric shock.
Please don’t secretly alter the structure and installation site of the fan.
Please don’t open the electrical control box while power on so as to prevent electric shock.
Please don’t operate the damaged devices, or it will bring serious consequences of personal injury.
Strictly prohibit the structural changes or parameter changes of the electrical control box, or it will cause equipment damage or
personal injury and death accident duo to the improper set.
In the electrical control box there includes high-voltage storage capacitor. When you operate the fan control device, please
wait for 3 minutes to let the voltage release out (notes: the displayer blackness is not the mark that the voltage has reached the
safety level) to prevent electric shock.
Strictly prohibit the operation when the safety space of the fun is insufficient.
Strictly prohibit the operation during the reverse back process of the fun’s operating space, and make sure whether there are
obstacles before starting.
Control switch Speed switch
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before operating the equipment, please read the product
instruction and clear the obstacles in the fan revolve area to
ensure there is enough safety space for the fan operation.
Warning: Please make sure to turn off the power supply first
before doing any electrical and fan maintenance and did by
professionals to avoid being wounded!
Attentions
1, confirm there is no obstruction and potential danger in the fan operation space ;
2, confirm the input power supply is correct and meet the product's requirement;
3, confirm the speed knob at the minimum position;
4, turn on the fan, turn the control switch from STOP position to RUN position;
5, after the fan starts, adjust speed knob to get the appropriate speed and best effect.
1, STOP device, turn the control switch from RUN position to STOP;
2, Power outage is prohibited during the fan normal operation.
Normal boot sequence of operations
Normal shutdown sequence of operations:
INSTALLATION GUIDE
BOREAS

INSTALLATION GUIDE
KALE FANS
www.kalefans.net
2019
Caution
The installation and layout of the circuit wiring must be performed by our professional qualified staff.
Please use the specified device component appointed by our company.
While the fan is running, please don’t cut off the power, otherwise it will cause damage to the fan. It should cut off
the power when the fan is drop-dead halt.
When the fan is in the corotation (inversion) state, please don’t switch the button to the opposite direction directly or
it will cause the mechanical failure.
8. Troubleshooting
Common causes for the malfunctioning operation:
1. The external power supply of the control box is not valid.
2. Open the master switch, and then turn on the three gears control switch, if the fan can still not work, please check
whether the speed knob is of the MIN state. Otherwise, please contract KaLe Environmental Technology(Shanghai)Corp.
Non-professional staffs do not open the electrical control box! For repair or adjustment, KaLe Environmental
Technology(Shanghai)Corp. will send you our trained professionals or engineers.
If you find the equipment is damaged or has abnormal sound, please stop running as soon as possible, cut off power
supply, and contact our service department.
Notes: Equipment damages due to the improper use are not covered by the warranty. Personal injuries and equipment
damages for your failure to comply with the contents of this manual, the Company will not bear any responsibilities.
8.1 Explanation of error codes
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No. Description Warning Alarm Trip
Lock
Error Cause of Problem
2 Live zero error X X Signal on terminal 53 or 60 is less than 50% of value set in
6-10 Terminal 53 Low Voltage, 6-12 Terminal 53 Low Currentand
6-22 Terminal 54 Low Current.
4Mains phase loss1) X X X Missing phase on supply side, or too high voltage imbalance. Check
supply voltage.
7DC over voltage1) X X Intermediate circuit voltage exceeds limit.
8DC under voltage1) X X Intermediate circuit voltage drops below “voltage warning low” limit.
9 Inverter overloaded X X More than 100% load for too long.
10 Motor ETR over temperature X X Motor is too hot due to more than 100% load for too long.
11 Motor thermistor over
temperature
X X Thermistor or thermistor connection is disconnected.
12 Torque limit X Torque exceeds value set in either par. 4-16 or 4-17.
13 Over Current X X X Inverter peak current limit is exceeded.
14 Earth fault X X X Discharge from output phases to ground.
16 Short Circuit X X Short-circuit in motor or on motor terminals.
17 Control word timeout X X No communication to frequency converter.
25 Brake resistor short-circuited X X Brake resistor is short-circuited, thus brake function is disconnected.
27 Brake chopper short-circuited X X Brake transistor is short-circuited, thus brake function is discon-
nected.
28 Brake check X Brake resistor is not connected/working
29 Power board over temp X X X Heat-sink cut-out temperature has been reached.
30 Motor phase U missing X X Motor phase U is missing. Check the phase.

9. Customer service
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After-sales service is very important for the stability of the equipment operation, because of this, KALE company always
offer customers high quality products and perfect after-sales service, at present, we had set up sales and after-sales
service centers in five major areas across the country to ensure that we can provide users with thoughtful, fast, high
quality and comprehensive after-sales service, make users feel relieved, without worry.
Product technical support
Combined with fan equipment installation, commissioning and operation process, we provide users with free training
about the product basic knowledge, use, maintenance technology and equipment related qualifications and certificates,
to ensure long term stable operation of equipment.
Support can be got through the following ways:
1, log in our company's official website www.kalefans.net, browse to download the latest product technical specification;
2, Contact our company after-sales service department at + 86-18016247962 to get support;
3, Contact corresponding salesman.
Our companies adhering to the customer first and provide the best service for you.
INSTALLATION GUIDE
BOREAS
31 Motor phase V missing X X Motor phase V is missing. Check the phase.
32 Motor phase W missing X X Motor phase W is missing. Check the phase.
38 Internal fault X X Contact local Danfoss supplier.
44 Earth fault X X Discharge from output phases to ground.
47 Control Voltage Fault X X 24 V DC may be overloaded.
51 AMA check Unom and Inom X Wrong setting for motor voltage and/or motor current.
52 AMA low Inom X Motor current is too low. Check settings.
59 Current limit X VLT overload.
63 Mechanical Brake Low X Actual motor current has not exceeded “release brake” current
within “start delay” time window.
80 Drive Initialised to Default Value X All parameter settings are initialized to default settings.
84 The connection between drive
and LCP is lost
X No communication between LCP and frequency converter
85 Button disabled X See parameter group 0-4* LCP
86 Copy fail X An error occurred while copying from frequency converter to LCP or
vice versa.
87 LCP data invalid X Occurs when copying from LCP if the LCP contains erroneous data -
or if no data was uploaded to the LCP.
88 LCP data not compatible X Occurs when copying from LCP if data are moved between
frequency converters with major differences in software versions.
89 Parameter read only X Occurs when trying to write to a read-only parameter.
90 Parameter database busy X LCP and RS485 connection are trying to update parameters simulta-
neously.
91 Parameter value is not valid in this
mode
X Occurs when trying to write an illegal value to a parameter.
92 Parameter value exceeds the
min/max limits
X Occurs when trying to set a value outside the range.
nw
run
Not While RUNning X Parameter can only be changed when the motor is stopped.
Err. A wrong password was entered X Occurs when using a wrong password for changing a password-
protected parameter.
1) These faults may be caused by mains distortions. Installing Danfoss Line Filter may rectify this problem.
No. Description Warning Alarm Trip
Lock
Error Cause of Problem

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10. Fan working condition
11. Quality assurance
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Details of the warranty of quality
Quality assurance is for the whole machine .The quality guarantee period is from the date of acceptance by
customers. Failure occurs during the quality guarantee period, such as products, our company provide free
consultation, maintenance services (including vulnerability free replacement of spare parts), quick response,
professional troubleshooting.
The damages caused following reasons are not in warranty scope:
(1) Improper use, maintenance and safekeeping;
(2) Buyer and user themselves dismount or remove the product;
(3) Force majeure factors (lightning, earthquake, typhoon, etc.) .
In order to take full advantage of the product's performance and extend its life, the installation environment if of
very important. Please install the fan in the environment as requested in the following table:
Environment Requirements
Installation site Indoors
Ambient temperature -15~+55℃
To improve the reliability, please don’t use the product in
the places where temperature changes rapidly.
Avoid freezing the product.
Humidity Below 95%RH
Surrounding Places with no corrosive gas and flammable gas
Places that metal powder, oil, water and other foreign matter
will not enter the controller
Places of less salt corrosion
Sea level elevation Less than 1000m

12. Warranty and maintenance
Our product design is maintenance-free, but in order to ensure the long life of the normal operation, the fan
should also be maintained regularly, especially when applied in harsh environments.
For any fan or inverter controller maintenance, please be sure that the fan stops running and cut off the controller
power to protect the safety of personnel.
If the fan is running with a serious abnormal noise or vibration, it indicates that there exists some damages to the
mechanical parts somewhere, and you should immediately shut down the fan and do a comprehensive inspection.
Product Warranty
Product warranty period: 1 years for complete machine after delivery.
For failures within the warranty period, please do not try to solve by your own, the company can send you a free
onsite service professional. But the following occasions are the paid services:
Failures caused by incorrect use.
Failures caused by your transform of our products without our permission.
Failures caused by natural disasters and fires.
Over the warranty period
Other failures caused by non-corporate responsibilities.
The abovementioned services are only available in mainland China; the Shanghai Company will not accept fault
diagnosis in foreign countries such. If customers wish to provide after-sales service abroad, it must be conclude and
sign a Foreign Service contract.
Our products are manufactured under strict quality control, and each set of the products have passed the rigorous
testing process before delivery.
When the product is used in the occasions that may cause major accident or loss due to the improper operation,
please configure the relevant security measures.
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INSTALLATION GUIDE
BOREAS
Interval The maintenance content
Test run Check the operation of the fan, any abnormal sound or vibration
2500h Clean the dust on the inverter
Clean the dust on the blades
5000h Check the mechanical fasterners to ensure that there's no looseness
Check wire cable to ensure that there's no damage
10000h Check the operation condition of power-driven device
Check the oil level of motor gearbox